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CRAWLER EXCAVATOR CX130B CRAWLER EXCAVATOR CX130B

SERVICE MANUAL SERVICE MANUAL

TABLE OF CONTENTS TABLE OF CONTENTS


DIVISION/SECTION SECTION N° REFERENCE N° DIVISION/SECTION SECTION N° REFERENCE N°
1 GENERAL INFORMATION 1 GENERAL INFORMATION
Safety, general information and standard torque data..................................... 1001 7-27691EN Safety, general information and standard torque data..................................... 1001 7-27691EN
General specifications and special torque setting ........................................... 1002 SC130B1002-2EN General specifications and special torque setting ........................................... 1002 SC130B1002-2EN
2 ENGINE 2 ENGINE
Removal and installation of the engine............................................................ 2000 SM130B2000-0EN Removal and installation of the engine............................................................ 2000 SM130B2000-0EN
Removal and installation of the fuel cooler, engine inter-cooler, Removal and installation of the fuel cooler, engine inter-cooler,
radiator and oil cooler.................................................................................. 2001 SM130B2001-0EN radiator and oil cooler.................................................................................. 2001 SM130B2001-0EN
Removal and installation of the turbo charger ................................................. 2004 SM130B2004-0EN Removal and installation of the turbo charger ................................................. 2004 SM130B2004-0EN
Removal and installation of EGR cooler and EGR valve ................................. 2005 SM130B2005-0EN Removal and installation of EGR cooler and EGR valve ................................. 2005 SM130B2005-0EN
Removal and installation of the engine hood................................................... 2006 SM130B2006-0EN Removal and installation of the engine hood................................................... 2006 SM130B2006-0EN
Engine specifications..............................................................................................* Engine specifications..............................................................................................*
Disassembly and assembly of the engine ..............................................................* Disassembly and assembly of the engine ..............................................................*
3 FUEL SYSTEM 3 FUEL SYSTEM
Removal and installation of the fuel tank......................................................... 3001 SM130B3001-0EN Removal and installation of the fuel tank......................................................... 3001 SM130B3001-0EN
Removal and installation of the supply pump and common rail ...................... 3004 SM130B3004-0EN Removal and installation of the supply pump and common rail ...................... 3004 SM130B3004-0EN
Removal and installation of the injectors ......................................................... 3005 SM130B3005-0EN Removal and installation of the injectors ......................................................... 3005 SM130B3005-0EN
Fuel engine system ................................................................................................* Fuel engine system ................................................................................................*
4 ELECTRICAL SYSTEM 4 ELECTRICAL SYSTEM
Electrical and engine functions and service support ....................................... 4001 SC130B4001-0EN Electrical and engine functions and service support ....................................... 4001 SC130B4001-0EN
Removal and installation of the starter motor .................................................. 4004 SM130B4004-0EN Removal and installation of the starter motor .................................................. 4004 SM130B4004-0EN
Removal and installation of the alternator ....................................................... 4005 SM130B4005-0EN Removal and installation of the alternator ....................................................... 4005 SM130B4005-0EN
Electrical equipment and electrical circuit diagrams........................................ 4020 SC210B4020-1EN Electrical equipment and electrical circuit diagrams........................................ 4020 SC210B4020-1EN
Engine error code (DTC) ................................................................................. 4021 SM130B4021-0EN Engine error code (DTC) ................................................................................. 4021 SM130B4021-0EN
Main body error code (DTC)............................................................................ 4022 SM130B4022-0EN Main body error code (DTC)............................................................................ 4022 SM130B4022-0EN
Troubleshooting, 4JJ1 engine.......................................................................... 4023 SM130B4023-0EN Troubleshooting, 4JJ1 engine.......................................................................... 4023 SM130B4023-0EN
5 UNDERCARRIAGE 5 UNDERCARRIAGE
Removal and installation of tracks ................................................................... 5001 SM130B5001-0EN Removal and installation of tracks ................................................................... 5001 SM130B5001-0EN
Rollers ............................................................................................................. 5003 SM130B5003-0EN Rollers ............................................................................................................. 5003 SM130B5003-0EN
Take-up roller................................................................................................... 5005 SM130B5005-0EN Take-up roller................................................................................................... 5005 SM130B5005-0EN
6 DRIVE TRAIN 6 DRIVE TRAIN
Removal and installation of the drive motor and Removal and installation of the drive motor and
final drive transmission................................................................................ 6001 SM130B6001-0EN final drive transmission................................................................................ 6001 SM130B6001-0EN
Disassembly and assembly of the drive motor and Disassembly and assembly of the drive motor and
final drive transmission................................................................................ 6002 SM130B6002-0EN final drive transmission................................................................................ 6002 SM130B6002-0EN
Removal and installation of the swing motor and Removal and installation of the swing motor and
swing reduction gear ................................................................................... 6003 SM130B6003-0EN swing reduction gear ................................................................................... 6003 SM130B6003-0EN
Disassembly and assembly of the swing reduction gear ................................. 6004 SM130B6004-0EN Disassembly and assembly of the swing reduction gear ................................. 6004 SM130B6004-0EN
7 UNDERCARRIAGE HYDRAULICS 7 UNDERCARRIAGE HYDRAULICS

* Consult the Engine Service Manual * Consult the Engine Service Manual

Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130BTOC-1EN November 2008 CNH Lep SM130BTOC-1EN November 2008
DIVISION/SECTION SECTION N° REFERENCE N° DIVISION/SECTION SECTION N° REFERENCE N°
8 UPPERSTRUCTURE HYDRAULICS 8 UPPERSTRUCTURE HYDRAULICS
Depressurising and decontaminating the hydraulic system, use of the Depressurising and decontaminating the hydraulic system, use of the
vacuum pump and bleeding the components..............................................8000 SM160B8000-0EN vacuum pump and bleeding the components..............................................8000 SM160B8000-0EN
Specifications, troubleshooting, checks and Specifications, troubleshooting, checks and
hydraulic pressure settings..........................................................................8001 SC130B8001-1EN hydraulic pressure settings..........................................................................8001 SC130B8001-1EN
Removal and installation of the hydraulic reservoir .........................................8002 SM130B8002-0EN Removal and installation of the hydraulic reservoir .........................................8002 SM130B8002-0EN
Removal and installation of the main hydraulic pump......................................8003 SM130B8003-0EN Removal and installation of the main hydraulic pump......................................8003 SM130B8003-0EN
Removal and installation of the main hydraulic control valve...........................8004 SM130B8004-0EN Removal and installation of the main hydraulic control valve...........................8004 SM130B8004-0EN
Removal and installation of the attachment cylinders......................................8005 SM130B8005-0EN Removal and installation of the attachment cylinders......................................8005 SM130B8005-0EN
Removal and installation of the hydraulic swivel ..............................................8006 SM130B8006-0EN Removal and installation of the hydraulic swivel ..............................................8006 SM130B8006-0EN
Removal and installation of the pilot blocs.......................................................8007 SM130B8007-0EN Removal and installation of the pilot blocs.......................................................8007 SM130B8007-0EN
Disassembly and assembly of the main hydraulic pump .................................8010 SM130B8010-0EN Disassembly and assembly of the main hydraulic pump .................................8010 SM130B8010-0EN
Disassembly and assembly of the main hydraulic control valve ......................8011 SM130B8011-0EN Disassembly and assembly of the main hydraulic control valve ......................8011 SM130B8011-0EN
Disassembly and assembly of the attachment cylinders .................................8012 SM130B8012-0EN Disassembly and assembly of the attachment cylinders .................................8012 SM130B8012-0EN
Disassembly and assembly of the hand control levers ....................................8013 SM130B8013-0EN Disassembly and assembly of the hand control levers ....................................8013 SM130B8013-0EN
Disassembly and assembly of the foot control levers ......................................8014 SM130B8014-0EN Disassembly and assembly of the foot control levers ......................................8014 SM130B8014-0EN
Disassembly and assembly of the cushion valve.............................................8016 SM130B8016-0EN Disassembly and assembly of the cushion valve.............................................8016 SM130B8016-0EN
Removal and installation of the safety valve ....................................................8017 SM130B8017-0EN Removal and installation of the safety valve ....................................................8017 SM130B8017-0EN
Disassembly and assembly of the swing motor ...............................................8019 SM130B8019-0EN Disassembly and assembly of the swing motor ...............................................8019 SM130B8019-0EN
Hydraulic functions ..........................................................................................8020 SC130B8020-1EN Hydraulic functions ..........................................................................................8020 SC130B8020-1EN
Hydraulic component functions........................................................................8030 SC130B8030-0EN Hydraulic component functions........................................................................8030 SC130B8030-0EN
9 UPPERSTRUCTURE 9 UPPERSTRUCTURE
Removal and installation of the counterweight ................................................9002 SM130B9002-0EN Removal and installation of the counterweight ................................................9002 SM130B9002-0EN
Removal and installation of the boom, dipper and bucket ...............................9003 SM130B9003-0EN Removal and installation of the boom, dipper and bucket ...............................9003 SM130B9003-0EN
Removal and installation of the seat ................................................................9004 SM130B9004-0EN Removal and installation of the seat ................................................................9004 SM130B9004-0EN
Removal and installation of the cab and cab equipment .................................9005 SM130B9005-0EN Removal and installation of the cab and cab equipment .................................9005 SM130B9005-0EN
Air conditioner functions and troubleshooting ..................................................9006 SC210B9006-1EN Air conditioner functions and troubleshooting ..................................................9006 SC210B9006-1EN
Air conditioning unit .........................................................................................9007 SM130B9007-0EN Air conditioning unit .........................................................................................9007 SM130B9007-0EN
Air conditioning components............................................................................9009 SM130B9009-0EN Air conditioning components............................................................................9009 SM130B9009-0EN
Large size hydraulic schematics ................................................................... Pocket 87725711A Large size hydraulic schematics ................................................................... Pocket 87725711A
Large size hydraulic schematics (2PC)......................................................... Pocket KNJ15290-E01-EN Large size hydraulic schematics (2PC)......................................................... Pocket KNJ15290-E01-EN
Large size electrical schematics ................................................................... Pocket 87594000B Large size electrical schematics ................................................................... Pocket 87594000B
NOTE: CNH Company reserves the right to make changes in the specification NOTE: CNH Company reserves the right to make changes in the specification
and design of the machine without prior notice and without incurring any obliga- and design of the machine without prior notice and without incurring any obliga-
tion to modify units previously sold. tion to modify units previously sold.
The description of the models shown in this manual has been made in accord- The description of the models shown in this manual has been made in accord-
ance with the technical specifications known as of the date of design of this ance with the technical specifications known as of the date of design of this
document. document.

Lep SM130BTOC-1EN Issued 11-08 Lep SM130BTOC-1EN Issued 11-08


1001

1001
Section Section
1001 1001

SAFETY, GENERAL INFORMATION SAFETY, GENERAL INFORMATION


AND TORQUE SPECIFICATIONS AND TORQUE SPECIFICATIONS

Copyright © 2006 CNH France S.A. Copyright © 2006 CNH France S.A.
Printed in France Printed in France
CNH Lep 7-27691EN February 2006 CNH Lep 7-27691EN February 2006
1001-2 1001-2

TABLE OF CONTENTS TABLE OF CONTENTS


GENERAL INFORMATION .......................................................................................................................................3 GENERAL INFORMATION .......................................................................................................................................3
SAFETY..................................................................................................................................................................... 4 SAFETY..................................................................................................................................................................... 4
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6 STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6

WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message that follows, as there is a risk of serious injury. ! this symbol, carefully read the message that follows, as there is a risk of serious injury.

Lep 7-27691EN Issued 02-06 Lep 7-27691EN Issued 02-06


1001-3 1001-3

GENERAL INFORMATION GENERAL INFORMATION


Cleanning Gears Cleanning Gears
Clean all metal parts except bearings, in a suitable Check all gears for wear and damage. Replace gears Clean all metal parts except bearings, in a suitable Check all gears for wear and damage. Replace gears
cleaning solvent or by steam cleaning. Do not use that have wear or damage. cleaning solvent or by steam cleaning. Do not use that have wear or damage.
caustic soda for steam cleaning. After cleaning, dry caustic soda for steam cleaning. After cleaning, dry
and put oil on all parts. Clean oil passages with Oil seals, O-rings and gaskets and put oil on all parts. Clean oil passages with Oil seals, O-rings and gaskets
compressed air. Clean bearings in a suitable cleaning compressed air. Clean bearings in a suitable cleaning
Always install new oil seals, O-rings and gaskets. Put Always install new oil seals, O-rings and gaskets. Put
solvent, dry the bearings completely and put oil on solvent, dry the bearings completely and put oil on
petroleum jelly on seals and O-rings. petroleum jelly on seals and O-rings.
the bearings. the bearings.

Inspection Shafts Inspection Shafts


Check all shafts that have wear or damage. Check Check all shafts that have wear or damage. Check
Check all parts when the parts are disassembled. Check all parts when the parts are disassembled.
the bearing and oil seal surfaces of the shafts for the bearing and oil seal surfaces of the shafts for
Replace all parts that have wear or damage. Small Replace all parts that have wear or damage. Small
damage. damage.
scoring or grooves can be removed with a hone or scoring or grooves can be removed with a hone or
crocus cloth. Complete a visual inspection for Service parts crocus cloth. Complete a visual inspection for Service parts
indications of wear, pitting and the replacement of indications of wear, pitting and the replacement of
parts necessary to prevent early failures. Always install genuine Case service parts. When parts necessary to prevent early failures. Always install genuine Case service parts. When
ordering refer to the Parts Catalog for the correct part ordering refer to the Parts Catalog for the correct part
Bearings number of the genuine Case replacement items. Bearings number of the genuine Case replacement items.
Failures due to the use of other than genuine Case Failures due to the use of other than genuine Case
Check bearings for easy action. If bearings have a Check bearings for easy action. If bearings have a
replacement parts are not covered by warranty. replacement parts are not covered by warranty.
loose fit or rough action replace the bearing. Wash loose fit or rough action replace the bearing. Wash
bearings with a suitable cleaning solvent and permit Lubrication bearings with a suitable cleaning solvent and permit Lubrication
to air dry. DO NOT DRY BEARINGS WITH to air dry. DO NOT DRY BEARINGS WITH
COMPRESSED AIR. Only use the oils and lubricants specified in the COMPRESSED AIR. Only use the oils and lubricants specified in the
Operator’s or Service Manuals. Failures due to the Operator’s or Service Manuals. Failures due to the
Needle bearings use of non-specified oils and lubricants are not Needle bearings use of non-specified oils and lubricants are not
covered by warranty. covered by warranty.
Before you press needle bearings in a bore always Before you press needle bearings in a bore always
remove any metal protrusions in the bore or edge of remove any metal protrusions in the bore or edge of
the bore. Before you press bearings into position put the bore. Before you press bearings into position put
petroleum jelly on the inside and outside diameter of petroleum jelly on the inside and outside diameter of
the bearings. the bearings.

Lep 7-27691EN Issued 02-06 Lep 7-27691EN Issued 02-06


1001-4 1001-4

SAFETY SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR This symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED. The message that follows the SAFETY IS INVOLVED. The message that follows the
! symbol contains important information about safety. Carefully
read the message. Make sure you fully understand the
! symbol contains important information about safety. Carefully
read the message. Make sure you fully understand the
causes of possible injury or death. causes of possible injury or death.

To prevent injury always follow the Warning, Caution To prevent injury always follow the Warning, Caution
and Danger notes in this section and throughout the and Danger notes in this section and throughout the
manual. WARNING: Before starting engine, study manual. WARNING: Before starting engine, study
Operator’s Manual safety messages. Read Operator’s Manual safety messages. Read
Put the warning tag shown below on the key for the all safety signs on machine. Clear the area of Put the warning tag shown below on the key for the all safety signs on machine. Clear the area of
keyswitch when servicing or repairing the machine. other persons. Learn and practice safe use keyswitch when servicing or repairing the machine. other persons. Learn and practice safe use
One warning tag is supplied with each machine. of controls before operating. One warning tag is supplied with each machine. of controls before operating.
Additional tags Part Number 331-4614 are available Additional tags Part Number 331-4614 are available
from your service parts supplier
! It is your responsibility to understand and
f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n from your service parts supplier
! It is your responsibility to understand and
f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n
. machine operation, service and to observe . machine operation, service and to observe
pertinent laws and regulations. Operator’s pertinent laws and regulations. Operator’s
WARNING: Read the operator’s manual to and Service Manuals may be obtained from WARNING: Read the operator’s manual to and Service Manuals may be obtained from
your Case dealer. your Case dealer.
! familiarize yourself with the correct control
functions.
! familiarize yourself with the correct control
functions.

WARNING: If you wear clothing that is too WARNING: If you wear clothing that is too
WARNING: Operate the machine and loose or do not use the correct safety WARNING: Operate the machine and loose or do not use the correct safety
equipment controls from the seat position equipment for your job, you can be injured. equipment controls from the seat position equipment for your job, you can be injured.
! only. Any other method could result in Always wear clothing that will not catch on ! only. Any other method could result in Always wear clothing that will not catch on
serious injury. ! objects. Extra safety equipment that can be serious injury. ! objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy protection, eye or face protection, heavy
WARNING: This is a one man machine, no gloves and reflector clothing. WARNING: This is a one man machine, no gloves and reflector clothing.
! riders allowed. ! riders allowed.

WARNING: When working in the area of the WARNING: When working in the area of the
! fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
! fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.

WARNING: When doing checks and tests WARNING: When doing checks and tests
on the equipment hydraulics, follow the on the equipment hydraulics, follow the
! procedures as they are written. DO NOT ! procedures as they are written. DO NOT
change the procedure. change the procedure.

WARNING: When putting the hydraulic WARNING: When putting the hydraulic
cylinders on this machine through the cylinders on this machine through the
! necessary cycles to check operation or to
remove air from a circuit, make sure all
! necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way. people are out of the way.

Lep 7-27691EN Issued 02-06 Lep 7-27691EN Issued 02-06


1001-5 1001-5

WARNING: Use insulated gloves or mittens WARNING: When servicing or repairing the WARNING: Use insulated gloves or mittens WARNING: When servicing or repairing the
! when working with hot parts. machine, keep the shop floor and operator’s ! when working with hot parts. machine, keep the shop floor and operator’s
compartment and steps free of oil, water, compartment and steps free of oil, water,
! grease, tools, etc. Use an oil absorbing ! grease, tools, etc. Use an oil absorbing
WARNING: Lower all attachments to the material and/or shop cloths as required. Use WARNING: Lower all attachments to the material and/or shop cloths as required. Use
ground or use stands to safely support the safe practices at all times. ground or use stands to safely support the safe practices at all times.
! attachments before you do any maintenance ! attachments before you do any maintenance
or service. or service.
WARNING: Some components of this WARNING: Some components of this
machine are very heavy. Use suitable lifting machine are very heavy. Use suitable lifting
WARNING: Pin sized and smaller streams ! equipment or additional help as instructed in WARNING: Pin sized and smaller streams ! equipment or additional help as instructed in
of hydraulic oil under pressure can penetrate this Service Manual. of hydraulic oil under pressure can penetrate this Service Manual.
the skin and result in serious infection. If the skin and result in serious infection. If
hydraulic oil under pressure does penetrate hydraulic oil under pressure does penetrate
the skin, seek medical treatment the skin, seek medical treatment
WARNING: Engine exhaust fumes can WARNING: Engine exhaust fumes can
immediately. Maintain all hoses and tubes in immediately. Maintain all hoses and tubes in
! good condition. Make sure all connections
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
! good condition. Make sure all connections
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
are tight. Make a replacement of any tube or
hose that is damaged or thought to be
! fumes from the area with an exhaust pipe
are tight. Make a replacement of any tube or
hose that is damaged or thought to be
! fumes from the area with an exhaust pipe
extension. Open the doors and get outside extension. Open the doors and get outside
damaged. DO NOT use your hand to check damaged. DO NOT use your hand to check
air into the area. air into the area.
for leaks, use a piece of cardboard or wood. for leaks, use a piece of cardboard or wood.

WARNING: When the battery electrolyte is WARNING: When the battery electrolyte is
WARNING: When removing hardened pins frozen, the battery can explode if (1), you try WARNING: When removing hardened pins frozen, the battery can explode if (1), you try
such as a pivot pin, or a hardened shaft, use to charge the battery, or (2), you try to jump such as a pivot pin, or a hardened shaft, use to charge the battery, or (2), you try to jump
start and run the engine. To prevent the start and run the engine. To prevent the
! a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
! battery electrolyte from freezing, try to keep ! a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
! battery electrolyte from freezing, try to keep
steel head hammer. the battery at full charge. If you do not follow steel head hammer. the battery at full charge. If you do not follow
these instructions, you or others in the area these instructions, you or others in the area
can be injured. can be injured.
WARNING: When using a hammer to WARNING: When using a hammer to
remove and install pivot pins or separate remove and install pivot pins or separate
parts using compressed air or using a parts using compressed air or using a
! grinder, wear eye protection that completely ! grinder, wear eye protection that completely
encloses the eyes (approved goggles or encloses the eyes (approved goggles or
other approved eye protectors). other approved eye protectors).

WARNING: Use suitable floor (service) WARNING: Use suitable floor (service)
jacks or chain hoist to raise wheels or tracks jacks or chain hoist to raise wheels or tracks
! off the floor. Always block machine in place ! off the floor. Always block machine in place
with suitable safety stands. with suitable safety stands.

Lep 7-27691EN Issued 02-06 Lep 7-27691EN Issued 02-06


1001-6 1001-6

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS
Tightening of cap screws, nuts Tightening of cap screws, nuts
Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the
order of tightening. order of tightening.

JS00481A JS00481A
Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or
suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then
tighten. tighten.

Torque table Torque table


Tighten cap screws and nuts according to the table below if there are no other special instructions. Tighten cap screws and nuts according to the table below if there are no other special instructions.

Cap Screw Name Size (Size) M6 M8 M10 M12 M14 M16 M18 M20 Cap Screw Name Size (Size) M6 M8 M10 M12 M14 M16 M18 M20

[mm] 10 13 17 19 22 24 27 30 [mm] 10 13 17 19 22 24 27 30
Spanner Spanner
[in.] 0.39 0.51 0.67 0.75 0.87 0.95 1.06 1.18 [in.] 0.39 0.51 0.67 0.75 0.87 0.95 1.06 1.18
Cap Screw Cap Screw
Tightening [Nm] 6.9 19.6 39.2 58.8 98.1 156.9 196.1 294.2 Tightening [Nm] 6.9 19.6 39.2 58.8 98.1 156.9 196.1 294.2
torque [lb-ft] 5.1 14.5 28.9 43.4 72.3 115.7 144.6 217 torque [lb-ft] 5.1 14.5 28.9 43.4 72.3 115.7 144.6 217

[mm] 5 6 8 10 12 14 14 17 [mm] 5 6 8 10 12 14 14 17
Spanner Spanner
Socket [in.] 0.20 0.24 0.32 0.39 0.47 0.55 0.55 0.67 Socket [in.] 0.20 0.24 0.32 0.39 0.47 0.55 0.55 0.67
Head Cap Head Cap
Screw [Nm] 8.8 21.6 42.1 78.5 117.7 176.5 245.2 343.2 Screw [Nm] 8.8 21.6 42.1 78.5 117.7 176.5 245.2 343.2
Tightening Tightening
torque torque
[lb-ft] 6.5 15.9 31.1 57.9 86.9 130.2 181 253.2 [lb-ft] 6.5 15.9 31.1 57.9 86.9 130.2 181 253.2

Lep 7-27691EN Issued 02-06 Lep 7-27691EN Issued 02-06


1002

1002
Section Section
1002 1002

SPECIFICATIONS SPECIFICATIONS
AND SPECIAL TORQUE SETTINGS AND SPECIAL TORQUE SETTINGS

Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SC130B1002-2EN March 2008 CNH Lep SC130B1002-2EN March 2008
1002-2 1002-2
TABLE OF CONTENTS TABLE OF CONTENTS

WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this
! symbol, carefully read the message which follows. Your safety depends on it. ! symbol, carefully read the message which follows. Your safety depends on it.

TYPE, SERIAL NUMBER TYPE, SERIAL NUMBER


AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 4 AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 4
Machine ....................................................................................................................................................................... 4 Machine ....................................................................................................................................................................... 4
Engine .......................................................................................................................................................................... 4 Engine .......................................................................................................................................................................... 4
Serial numbers of the components .............................................................................................................................. 4 Serial numbers of the components .............................................................................................................................. 4

FLUIDS AND LUBRICANTS ............................................................................................................................................ 5 FLUIDS AND LUBRICANTS ............................................................................................................................................ 5


Hydraulic fluid .............................................................................................................................................................. 5 Hydraulic fluid .............................................................................................................................................................. 5
Transmission component oil ........................................................................................................................................ 5 Transmission component oil ........................................................................................................................................ 5
Grease ......................................................................................................................................................................... 5 Grease ......................................................................................................................................................................... 5
Engine Oil .................................................................................................................................................................... 6 Engine Oil .................................................................................................................................................................... 6
Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 7 Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 7
Anti-freeze/Anti-corrosion............................................................................................................................................. 9 Anti-freeze/Anti-corrosion............................................................................................................................................. 9
Environment ................................................................................................................................................................. 9 Environment ................................................................................................................................................................. 9
Plastic and resin parts.................................................................................................................................................. 9 Plastic and resin parts.................................................................................................................................................. 9

SPECIFICATIONS ......................................................................................................................................................... 10 SPECIFICATIONS ......................................................................................................................................................... 10


Main data ................................................................................................................................................................... 10 Main data ................................................................................................................................................................... 10
Performance .............................................................................................................................................................. 10 Performance .............................................................................................................................................................. 10
Complete machine dimensions .................................................................................................................................. 10 Complete machine dimensions .................................................................................................................................. 10
Main body dimensions ............................................................................................................................................... 11 Main body dimensions ............................................................................................................................................... 11
Engine ........................................................................................................................................................................ 12 Engine ........................................................................................................................................................................ 12
Cooling system .......................................................................................................................................................... 12 Cooling system .......................................................................................................................................................... 12
Capacity of coolant and lubricants ............................................................................................................................. 12 Capacity of coolant and lubricants ............................................................................................................................. 12
Air conditioning .......................................................................................................................................................... 12 Air conditioning .......................................................................................................................................................... 12
Hydraulic oil filter........................................................................................................................................................ 12 Hydraulic oil filter........................................................................................................................................................ 12
Fuel filter .................................................................................................................................................................... 12 Fuel filter .................................................................................................................................................................... 12
Operating devices ...................................................................................................................................................... 13 Operating devices ...................................................................................................................................................... 13
Hydraulic system........................................................................................................................................................ 14 Hydraulic system........................................................................................................................................................ 14
Swing unit .................................................................................................................................................................. 19 Swing unit .................................................................................................................................................................. 19
Travel lower body....................................................................................................................................................... 19 Travel lower body....................................................................................................................................................... 19
Work Unit ................................................................................................................................................................... 20 Work Unit ................................................................................................................................................................... 20
Digging force (ISO 6015) ........................................................................................................................................... 21 Digging force (ISO 6015) ........................................................................................................................................... 21

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1002-3 1002-3
COMPONENT WEIGHT .................................................................................................................................................22 COMPONENT WEIGHT .................................................................................................................................................22
Major component weight (CX130B)............................................................................................................................22 Major component weight (CX130B)............................................................................................................................22

COMPONENT WEIGHT .................................................................................................................................................23 COMPONENT WEIGHT .................................................................................................................................................23


Major component weight (CX130B 2PC, CX130B 2PC (with Blade)) ........................................................................23 Major component weight (CX130B 2PC, CX130B 2PC (with Blade)) ........................................................................23
Other component weight.............................................................................................................................................24 Other component weight.............................................................................................................................................24

DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY ...................................................................................18 DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY ...................................................................................18
Sprocket......................................................................................................................................................................18 Sprocket......................................................................................................................................................................18
Idler wheel ..................................................................................................................................................................19 Idler wheel ..................................................................................................................................................................19
Upper roller .................................................................................................................................................................20 Upper roller .................................................................................................................................................................20
Lower roller .................................................................................................................................................................21 Lower roller .................................................................................................................................................................21
Track...........................................................................................................................................................................22 Track...........................................................................................................................................................................22

DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS ..................................................................23 DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS ..................................................................23
1. Boom foot/Frame ....................................................................................................................................................23 1. Boom foot/Frame ....................................................................................................................................................23
2. Boom cylinder foot/Frame.......................................................................................................................................24 2. Boom cylinder foot/Frame.......................................................................................................................................24
3. Boom cylinder head/Boom......................................................................................................................................24 3. Boom cylinder head/Boom......................................................................................................................................24
4. Dipper cylinder foot/Boom ......................................................................................................................................25 4. Dipper cylinder foot/Boom ......................................................................................................................................25
5. Boom/Dipper...........................................................................................................................................................25 5. Boom/Dipper...........................................................................................................................................................25
6. Dipper cylinder head/Dipper ...................................................................................................................................26 6. Dipper cylinder head/Dipper ...................................................................................................................................26
7. Bucket cylinder foot/Dipper.....................................................................................................................................26 7. Bucket cylinder foot/Dipper.....................................................................................................................................26
8. Connecting rod/Dipper............................................................................................................................................27 8. Connecting rod/Dipper............................................................................................................................................27
9. Compensator/Bucket ..............................................................................................................................................27 9. Compensator/Bucket ..............................................................................................................................................27
10. Connecting rod/Compensator/Bucket cylinder head ............................................................................................28 10. Connecting rod/Compensator/Bucket cylinder head ............................................................................................28
11. Dipper/Bucket .......................................................................................................................................................29 11. Dipper/Bucket .......................................................................................................................................................29

DIMENSIONS AND WEAR LIMITS OF BLADE MOBILE JOINTS .................................................................................30 DIMENSIONS AND WEAR LIMITS OF BLADE MOBILE JOINTS .................................................................................30
1. Blade/Blade cylinder head ......................................................................................................................................30 1. Blade/Blade cylinder head ......................................................................................................................................30
2. Blade cylinder foot/Frame.......................................................................................................................................31 2. Blade cylinder foot/Frame.......................................................................................................................................31
3. Blade/Frame ...........................................................................................................................................................31 3. Blade/Frame ...........................................................................................................................................................31

SPECIAL TORQUE SETTINGS......................................................................................................................................32 SPECIAL TORQUE SETTINGS......................................................................................................................................32

MACHINE OVERALL DIMENSIONS ..............................................................................................................................36 MACHINE OVERALL DIMENSIONS ..............................................................................................................................36

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1002-4 1002-4
TYPE, SERIAL NUMBER TYPE, SERIAL NUMBER
AND YEAR OF MANUFACTURE OF THE MACHINE AND YEAR OF MANUFACTURE OF THE MACHINE
For all part orders, request for information or assistance, always specify the type and the serial number of the machine to For all part orders, request for information or assistance, always specify the type and the serial number of the machine to
your Case dealer. your Case dealer.
Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the
serial numbers of the hydraulic and mechanical components. serial numbers of the hydraulic and mechanical components.

Machine Machine

1 1

2 2

3 3

CT04A171A CT04A171A

(1) Type .............................................................................................................................................................................. (1) Type ..............................................................................................................................................................................


(2) Serial number................................................................................................................................................................ (2) Serial number................................................................................................................................................................
(3) Year of manufacture ...................................................................................................................................................... (3) Year of manufacture ......................................................................................................................................................

Engine Engine
Make and type .................................................................................................................................................................... Make and type ....................................................................................................................................................................
Serial number ..................................................................................................................................................................... Serial number .....................................................................................................................................................................

Serial numbers of the components Serial numbers of the components


Hydraulic pump .................................................................................................................................................................. Hydraulic pump ..................................................................................................................................................................
Swing reduction gear.......................................................................................................................................................... Swing reduction gear..........................................................................................................................................................
Travel reduction gears ........................................................................................................................................................ Travel reduction gears ........................................................................................................................................................
Control valve....................................................................................................................................................................... Control valve.......................................................................................................................................................................

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1002-5 1002-5
FLUIDS AND LUBRICANTS FLUIDS AND LUBRICANTS
Lubricants must have the correct properties for each application. Lubricants must have the correct properties for each application.

WARNING: The conditions of use for individual fluids and lubricants must be respected. WARNING: The conditions of use for individual fluids and lubricants must be respected.
! !
Hydraulic fluid Hydraulic fluid
CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system. CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system.
The type of fluid to be used depends on the ambient temperature. The type of fluid to be used depends on the ambient temperature.
Temperate climates: -20°C to +40°C (-4° to 104° F) Temperate climates: -20°C to +40°C (-4° to 104° F)
CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV) CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Hot climates: 0°C to +50°C (32° to 122° F) Hot climates: 0°C to +50°C (32° to 122° F)
CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP) CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP)
Cold climates: -25°C to +20°C (-13° to 68° F) Cold climates: -25°C to +20°C (-13° to 68° F)
CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2) CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2)
Biodegradable fluid: -30°C to +40°C (-22° to 104° F) Biodegradable fluid: -30°C to +40°C (-22° to 104° F)
This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advised to drain the circuit This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advised to drain the circuit
completely before refilling with this fluid. completely before refilling with this fluid.
CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV) CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)

Transmission component oil Transmission component oil


Extreme pressure oil used for enclosed transmission components. Extreme pressure oil used for enclosed transmission components.
CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A) CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)

Grease Grease
CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2) CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide. "Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide.
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2) CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and calcium. "Extreme Pressure" multipurpose grease with lithium soap and calcium.
CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2) CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap. "Extreme Pressure" multipurpose grease with lithium soap.
Hydraulic breakers Hydraulic breakers
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2). CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).

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1002-6 1002-6
Engine Oil Engine Oil
THE CASE/AKCELA No. 1 engine oil is recommended THE CASE/AKCELA No. 1 engine oil is recommended
for your engine. This oil ensures proper lubrication of for your engine. This oil ensures proper lubrication of
your engine for all operating conditions. your engine for all operating conditions.
If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL" If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL"
cannot be obtained, use the oil corresponding to one of cannot be obtained, use the oil corresponding to one of
the following categories: ACEA E7. API CI-4. the following categories: ACEA E7. API CI-4.

CP02N001 CP02N001

Oil viscosity / Oil range Oil viscosity / Oil range

1 1
2 2
2 2
3 3
3 3

CT02M001 CT02M001

(1) With mineral base (1) With mineral base


(2) With semi-synthetic base (2) With semi-synthetic base
(3) With synthetic base (3) With synthetic base

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1002-7 1002-7
Engine fuel, maintenance of fuel filters and fuel storage Engine fuel, maintenance of fuel filters and fuel storage
In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and
they are to be used under high-pressure conditions. they are to be used under high-pressure conditions.
Therefore, the specified fuel must be used for the engine. Therefore, the specified fuel must be used for the engine.
As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it
may invite a serious breakdown. may invite a serious breakdown.
In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the gen- In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the gen-
uine filter is essential. uine filter is essential.
The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel
and the fuel elements. and the fuel elements.
Fuel to be applied Fuel to be applied
Selection of fuel Selection of fuel
Following conditions must be met for the diesel engines, that is the one; Following conditions must be met for the diesel engines, that is the one;
1 In which no dust even fine one is mixed, 1 In which no dust even fine one is mixed,
2 With proper viscosity, 2 With proper viscosity,
3 With high cetane rating, 3 With high cetane rating,
4 With good flow properties in lower temperature, 4 With good flow properties in lower temperature,
5 With not much sulfur content, and 5 With not much sulfur content, and
6 With less content of carbon residue 6 With less content of carbon residue
Applicable standards for diesel fuel Applicable standards for diesel fuel

Applicable Standard Recommendation Applicable Standard Recommendation

JIS (Japanese Industrial Standard) NO.2 JIS (Japanese Industrial Standard) NO.2

DIN (Deutsche Industrie Normen) DIN 51601 DIN (Deutsche Industrie Normen) DIN 51601

SAE (Society of Automotive Engineers) SAE (Society of Automotive Engineers)

Based on SAE-J-313C NO. 2-D Based on SAE-J-313C NO. 2-D

BS (British Standard) BS (British Standard)

Based on BS/2869-197 Class A-1 Based on BS/2869-197 Class A-1

EN590 EN590

If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details. If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details.
Requirements for diesel fuel Requirements for diesel fuel
Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big
influence on its service durability and service life. influence on its service durability and service life.
Be sure to observe the following requirements for selecting fuel. Be sure to observe the following requirements for selecting fuel.
Sulfur content............................................................................... 2500 ppm or less Sulfur content............................................................................... 2500 ppm or less
HFRR* ......................................................................................... 460 mm or less HFRR* ......................................................................................... 460 mm or less
Water content .............................................................................. 0.05 wt% or less Water content .............................................................................. 0.05 wt% or less
* HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel. * HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel.
Sulfur content reacts to moisture to change into sulfuric acid after combustion. Sulfur content reacts to moisture to change into sulfuric acid after combustion.
Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear. Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear.
In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be
worse which results in acceleration of wear of sliding portions. worse which results in acceleration of wear of sliding portions.
HFRR is an index that indicates lubricating property of a fuel. HFRR is an index that indicates lubricating property of a fuel.
Large value of the index means poor lubrication so that seizure of the machine components may result if such a Large value of the index means poor lubrication so that seizure of the machine components may result if such a
fuel is used. fuel is used.
Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out. Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out.

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1002-8 1002-8
If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in accelera- If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in accelera-
tion of wear. tion of wear.
Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter. Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter.
IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of conden- IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of conden-
sation. sation.
This may also cause wear and seizure of the machine components. This may also cause wear and seizure of the machine components.
If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice
allowing the fuel line to be clogged. allowing the fuel line to be clogged.
IMPORTANT : Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the criteria IMPORTANT : Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the criteria
described above. described above.
IMPORTANT : If a fuel which does not meet the specifications and the requirements for the diesel engine, function and IMPORTANT : If a fuel which does not meet the specifications and the requirements for the diesel engine, function and
performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine or performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine or
an accident may be invited. an accident may be invited.
Guarantee will not be given to a breakdown caused by the use of a improper fuel. Guarantee will not be given to a breakdown caused by the use of a improper fuel.
Some fuels are used with engine oil or additives mixed together with diesel engine fuel. Some fuels are used with engine oil or additives mixed together with diesel engine fuel.
In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated. In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated.
It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not
meet the specifications and the requirements is used. meet the specifications and the requirements is used.
Use the specified fuel for compliance of the exhaust gas control. Use the specified fuel for compliance of the exhaust gas control.
IMPORTANT : It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to fol- low the IMPORTANT : It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to fol- low the
items below for the engine oil selection and maintenance of engine parts. Guarantee will not be given to breakdowns items below for the engine oil selection and maintenance of engine parts. Guarantee will not be given to breakdowns
caused by not to follow these items. caused by not to follow these items.
1 Selection of engine oil 1 Selection of engine oil
Use API grade CF-4 or JASO grade DH-1. Use API grade CF-4 or JASO grade DH-1.
2 Exchange the engine oil and engine oil filter element by the periodical interval reported on the Operator’s 2 Exchange the engine oil and engine oil filter element by the periodical interval reported on the Operator’s
Manual. Manual.
3 Inspect and exchange the EGR (*)parts and fuel injector parts of engine every 3000 hour of use. 3 Inspect and exchange the EGR (*)parts and fuel injector parts of engine every 3000 hour of use.
* EGR: Exhaust Gas Recircultion * EGR: Exhaust Gas Recircultion
Maintenance of fuel filters Maintenance of fuel filters
Be sure to use the genuine fuel filters. Be sure to use the genuine fuel filters.
The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional fil- The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional fil-
ters to improve protection of machine equipment. ters to improve protection of machine equipment.
If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine
equipment can wear out in a short period of time. equipment can wear out in a short period of time.
IMPORTANT : If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by the use IMPORTANT : If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by the use
of a wrong filter. of a wrong filter.
Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine. Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine.
Be sure to use the genuine fuel filters and replace them at the periodic intervals reported on the operator’s Man- Be sure to use the genuine fuel filters and replace them at the periodic intervals reported on the operator’s Man-
ual. ual.
IMPORTANT : Since the pre-filter also has a function of water separation, discharge water and sediment when the float IMPORTANT : Since the pre-filter also has a function of water separation, discharge water and sediment when the float
reaches lower part of the filter elements. CHECK EVERY DAY before to start the engine. reaches lower part of the filter elements. CHECK EVERY DAY before to start the engine.
Time to replace filters may be advanced according to properties of the fuel being supplied. Time to replace filters may be advanced according to properties of the fuel being supplied.
• Therefore, take measures to prevent dust or water from being entered in the fuel tank when sup- plying fuel. • Therefore, take measures to prevent dust or water from being entered in the fuel tank when sup- plying fuel.
• When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply • When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply
clean fuel standing above a precipitate. clean fuel standing above a precipitate.
• If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel • If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel
tank of the machine to supply clean fuel. tank of the machine to supply clean fuel.
Water drain cock is provided on the bottom side of the fuel tank. Water drain cock is provided on the bottom side of the fuel tank.
• Drain water before starting the engine every morning. • Drain water before starting the engine every morning.
• In addition, remove the cover under the tank once a year to clean up inside of the tank. • In addition, remove the cover under the tank once a year to clean up inside of the tank.

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1002-9 1002-9
Fuel storage Fuel storage
Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced
to the presence of water in the fuel. to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off
water and impurities regularly. water and impurities regularly.

Anti-freeze/Anti-corrosion Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing. Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710) CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710)
For areas where the temperature goes down to -38°C (-36.4°F), mix 50/50 with water. For areas where the temperature goes down to -38°C (-36.4°F), mix 50/50 with water.
IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the
system. system.

Environment Environment
Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always
think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles. think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.
Contact your local ecological recycling centre or your CASE Dealer to obtain information on the correct method of dis- Contact your local ecological recycling centre or your CASE Dealer to obtain information on the correct method of dis-
posing of these lubricants. posing of these lubricants.

Plastic and resin parts Plastic and resin parts


When cleaning plastic parts, the console, the instrument panel, the indicators etc... avoid using petrol, kerosene, paint When cleaning plastic parts, the console, the instrument panel, the indicators etc... avoid using petrol, kerosene, paint
solvents etc... Use only water, soap and a soft cloth. solvents etc... Use only water, soap and a soft cloth.
The use of petrol, kerosene, paint solvents etc... causes discoloration, cracks or deformation of these parts. The use of petrol, kerosene, paint solvents etc... causes discoloration, cracks or deformation of these parts.

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1002-10 1002-10
SPECIFICATIONS SPECIFICATIONS
Main data Main data
Model name. CX130B, CX130B (LC), CX130B (Blade), CX130B (2PC), CX130B (2PC with Blade) Hydraulic Excavator Model name. CX130B, CX130B (LC), CX130B (Blade), CX130B (2PC), CX130B (2PC with Blade) Hydraulic Excavator
Operating weight Operating weight
CX130B.........................................................................................................................................12700 kg (27999 lbs) CX130B.........................................................................................................................................12700 kg (27999 lbs)
CX130B (LC).................................................................................................................................13000 kg (28660 lbs) CX130B (LC).................................................................................................................................13000 kg (28660 lbs)
CX130B (Blade) ........................................................................................................................... 13500 Kg (29762 lbs) CX130B (Blade) ........................................................................................................................... 13500 Kg (29762 lbs)
CX130B (2PC) ............................................................................................................................. 13200 Kg (29101 lbs) CX130B (2PC) ............................................................................................................................. 13200 Kg (29101 lbs)
CX130B (2PC Blade) ................................................................................................................... 14000 Kg (30865 lbs) CX130B (2PC Blade) ................................................................................................................... 14000 Kg (30865 lbs)
Engine output ...................................................................................................................................... 89.2 kW / 2200 rpm Engine output ...................................................................................................................................... 89.2 kW / 2200 rpm
Engine output CX130B (2PC); CX130B (2PC with blade)................................................................... 70.9 kW / 2000 rpm Engine output CX130B (2PC); CX130B (2PC with blade)................................................................... 70.9 kW / 2000 rpm
Performance Performance
Swing speed.....................................................................................................................................................14.3 Tr/min. Swing speed.....................................................................................................................................................14.3 Tr/min.
Travel speed Travel speed
Low Speed ..................................................................................................................................... 3.4 km/h (2.11 mph) Low Speed ..................................................................................................................................... 3.4 km/h (2.11 mph)
High Speed .................................................................................................................................... 5.6 km/h (3.48 mph) High Speed .................................................................................................................................... 5.6 km/h (3.48 mph)
Maximum drawbar pull .....................................................................................................................115 kN (25853.03 lbf) Maximum drawbar pull .....................................................................................................................115 kN (25853.03 lbf)
Grade ability ....................................................................................................................................................... 70% (35°) Grade ability ....................................................................................................................................................... 70% (35°)
Ground pressure Ground pressure
CX130B.........................................................................................................34 kPa (600 mm (23.62 in) grouser shoe) CX130B.........................................................................................................34 kPa (600 mm (23.62 in) grouser shoe)
CX130B (LC).................................................................................................32 kPa (600 mm (23.62 in) grouser shoe) CX130B (LC).................................................................................................32 kPa (600 mm (23.62 in) grouser shoe)
CX130B (Blade) ............................................................................................41 kPa (600 mm (23.62 in) grouser shoe) CX130B (Blade) ............................................................................................41 kPa (600 mm (23.62 in) grouser shoe)
CX130B (2PC) ..............................................................................................36 kPa (600 mm (23.62 in) grouser shoe) CX130B (2PC) ..............................................................................................36 kPa (600 mm (23.62 in) grouser shoe)
CX130B (2PC Blade) ....................................................................................38 kPa (600 mm (23.62 in) grouser shoe) CX130B (2PC Blade) ....................................................................................38 kPa (600 mm (23.62 in) grouser shoe)
Complete machine dimensions Complete machine dimensions
Arm (dipper) Arm (dipper)
CX130B (Standard boom) 2500 mm 2110 mm 3010 mm CX130B (Standard boom) 2500 mm 2110 mm 3010 mm
(98.42 in) (83.07 in) (118.50 in) (98.42 in) (83.07 in) (118.50 in)
3880 mm 3880 mm 3880 mm 3880 mm 3880 mm 3880 mm
Lenght (without attachment) Lenght (without attachment)
(152.75 in) (152.75 in) (152.75 in) (152.75 in) (152.75 in) (152.75 in)
7620 mm 7610 mm 7640 mm 7620 mm 7610 mm 7640 mm
Lenght (with attachment) Lenght (with attachment)
(300 in) (299.60 in) (300.78 in) (300 in) (299.60 in) (300.78 in)
2810 mm 2710 mm 2820 mm 2810 mm 2710 mm 2820 mm
Height (with attachment) Height (with attachment)
(110.63 in) (106.69 in) (111.02 in) (110.63 in) (106.69 in) (111.02 in)

Arm (dipper) Arm (dipper)


CX130B (Blade) 2500 mm 2110 mm 3010 mm CX130B (Blade) 2500 mm 2110 mm 3010 mm
(98.42 in) (83.07 in) (118.50 in) (98.42 in) (83.07 in) (118.50 in)
4020 mm 4020 mm 4020 mm 4020 mm 4020 mm 4020 mm
Lenght (without attachment) Lenght (without attachment)
(158.26 in) (158.26 in) (158.26 in) (158.26 in) (158.26 in) (158.26 in)
7760 mm 7750 mm 7785 mm 7760 mm 7750 mm 7785 mm
Lenght (with attachment) Lenght (with attachment)
(305.51 in) (305.11 in) (306.49 in) (305.51 in) (305.11 in) (306.49 in)
2810 mm 2710 mm 2820 mm 2810 mm 2710 mm 2820 mm
Height (with attachment) Height (with attachment)
(110.62 in) (106.69 in) (111.02 in) (110.62 in) (106.69 in) (111.02 in)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-11 1002-11

Arm (dipper) Arm (dipper)


CX130B (2PC) 2500 mm 2110 mm 3010 mm CX130B (2PC) 2500 mm 2110 mm 3010 mm
(98.42 in) (83.07 in) (118.50 in) (98.42 in) (83.07 in) (118.50 in)
3880 mm 3880 mm 3880 mm 3880 mm 3880 mm 3880 mm
Lenght (without attachment) Lenght (without attachment)
(152.75 in) (152.75 in) (152.75 in) (152.75 in) (152.75 in) (152.75 in)
7730 mm 7720 mm 7750 mm 7730 mm 7720 mm 7750 mm
Lenght (with attachment) Lenght (with attachment)
(304.33 in) (303.94 in) (305.12 in) (304.33 in) (303.94 in) (305.12 in)
2730 mm 2650 mm 2780 mm 2730 mm 2650 mm 2780 mm
Height (with attachment) Height (with attachment)
(107.48 in) (104.33 in) (109.45 in) (107.48 in) (104.33 in) (109.45 in)

Arm (dipper) Arm (dipper)


CX130B (2PC Blade) 2500 mm 2110 mm 3010 mm CX130B (2PC Blade) 2500 mm 2110 mm 3010 mm
(98.42 in) (83.07 in) (118.50 in) (98.42 in) (83.07 in) (118.50 in)
4020 mm 4020 mm 4020 mm 4020 mm 4020 mm 4020 mm
Lenght (without attachment) Lenght (without attachment)
(158.26 in) (158.26 in) (158.26 in) (158.26 in) (158.26 in) (158.26 in)
7870 mm 7860 mm 7890 mm 7870 mm 7860 mm 7890 mm
Lenght (with attachment) Lenght (with attachment)
(309.84 in) (309.45 in) (310.63 in) (309.84 in) (309.45 in) (310.63 in)
2730 mm 2650 mm 2780 mm 2730 mm 2650 mm 2780 mm
Height (with attachment) Height (with attachment)
(107.48 in) (104.33 in) (109.45 in) (107.48 in) (104.33 in) (109.45 in)

Main body dimensions Main body dimensions


Main body width and length ............................................................................................ See machine overall dimensions Main body width and length ............................................................................................ See machine overall dimensions
Upper side swing body width ................................................................................................................. 2540 mm (100 in) Upper side swing body width ................................................................................................................. 2540 mm (100 in)
Cab width ............................................................................................................................................ 1000 mm (39.37 in) Cab width ............................................................................................................................................ 1000 mm (39.37 in)
Main body height............................................................................................................................... 2820 mm (111.02 in) Main body height............................................................................................................................... 2820 mm (111.02 in)
Tail swing radius .................................................................................................................................. 2130 mm (83.86 in) Tail swing radius .................................................................................................................................. 2130 mm (83.86 in)
Swing body tail distance...................................................................................................................... 2130 mm (83.86 in) Swing body tail distance...................................................................................................................... 2130 mm (83.86 in)
Swing body rear section bottom height ................................................................................................. 895 mm (35.24 in) Swing body rear section bottom height ................................................................................................. 895 mm (35.24 in)
Distance between tumblers............................................................................................................... 2790 mm (109.84 in) Distance between tumblers............................................................................................................... 2790 mm (109.84 in)
CX130B (LC) ................................................................................................................................ 3040 mm (119.68 in) CX130B (LC) ................................................................................................................................ 3040 mm (119.68 in)
Overall track length ........................................................................................................................... 3500 mm (137.79 in) Overall track length ........................................................................................................................... 3500 mm (137.79 in)
CX130B (LC) ................................................................................................................................ 3760 mm (148.03 in) CX130B (LC) ................................................................................................................................ 3760 mm (148.03 in)
Overall track width............................................................................................................................. 2590 mm (101.97 in) Overall track width............................................................................................................................. 2590 mm (101.97 in)
Distance between tracks ..................................................................................................................... 1990 mm (78.35 in) Distance between tracks ..................................................................................................................... 1990 mm (78.35 in)
Width of track shoe ................................................................................600 mm (23.62 in), (Optional: 500 mm (19.68 in) Width of track shoe ................................................................................600 mm (23.62 in), (Optional: 500 mm (19.68 in)
CX130B (2PC, 2PC Blade) ............................................................................................................... 600 mm (23.62 in) CX130B (2PC, 2PC Blade) ............................................................................................................... 600 mm (23.62 in)
Minimum ground clearance (To bottom of lower frame) ........................................................................ 460 mm (18.11 in) Minimum ground clearance (To bottom of lower frame) ........................................................................ 460 mm (18.11 in)
CX130B (2PC) .................................................................................................................................. 440 mm (17.32 in) CX130B (2PC) .................................................................................................................................. 440 mm (17.32 in)
CX130B (blade); (2PC Blade)........................................................................................................... 380 mm (14.96 in) CX130B (blade); (2PC Blade)........................................................................................................... 380 mm (14.96 in)
Dozer Blade Dozer Blade
Width of Blade .............................................................................................................................. 2590 mm (101.97 in) Width of Blade .............................................................................................................................. 2590 mm (101.97 in)
Height of Blade ................................................................................................................................. 570 mm (22.44 in) Height of Blade ................................................................................................................................. 570 mm (22.44 in)
Maximum lift above ground............................................................................................................... 380 mm (14.96 in) Maximum lift above ground............................................................................................................... 380 mm (14.96 in)
Minimum drop below ground............................................................................................................. 370 mm (14.57 in) Minimum drop below ground............................................................................................................. 370 mm (14.57 in)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-12 1002-12
Engine Engine
Name............................................................................................................................................................ISUZU, 4JJ1X Name............................................................................................................................................................ISUZU, 4JJ1X
Type: ....................................................... 4-cycle, water-cooled, overhead camshaft, vertical in-line, direct injection type Type: ....................................................... 4-cycle, water-cooled, overhead camshaft, vertical in-line, direct injection type
............................................................................................................................... (electronic control), with turbocharger. ............................................................................................................................... (electronic control), with turbocharger.
No. of cylinders - bore x stroke.........................................................................4 - Ø95.4 mm x 104.9 mm (3.76 x 4.13 in) No. of cylinders - bore x stroke.........................................................................4 - Ø95.4 mm x 104.9 mm (3.76 x 4.13 in)
Displacement........................................................................................................................................2999 cc (183 cu-in) Displacement........................................................................................................................................2999 cc (183 cu-in)
Compression ratio ....................................................................................................................................................... 17.5 Compression ratio ....................................................................................................................................................... 17.5
Rated output......................................................................................................................................70.9 kW / 2000 min-1 Rated output......................................................................................................................................70.9 kW / 2000 min-1
Maximum torque.......................................................................................................... 359 N.m (264.78 lb-ft) / 1600 min-1 Maximum torque.......................................................................................................... 359 N.m (264.78 lb-ft) / 1600 min-1
Engine dimensions (LxWxH) ........................................................................... 928x760x888 mm (36.53 x29.92x34.96 in) Engine dimensions (LxWxH) ........................................................................... 928x760x888 mm (36.53 x29.92x34.96 in)
Oil pan ...............................................................................................................................All direction 0.61 rad, inclinable Oil pan ...............................................................................................................................All direction 0.61 rad, inclinable
Oil pan capacity.................................................. Maximum: 15 L (3.92 gal) Minimum: 11 L (2.91 gal) (excluding oil filter) Oil pan capacity.................................................. Maximum: 15 L (3.92 gal) Minimum: 11 L (2.91 gal) (excluding oil filter)
Direction of rotation ...................................................................................................................... Right (as seen from fan) Direction of rotation ...................................................................................................................... Right (as seen from fan)
Starter, reduction type ...................................................................................................................................... .24 V, 4 kW Starter, reduction type ...................................................................................................................................... .24 V, 4 kW
Alternator, AC type ............................................................................................................................................. 24 V, 50 A Alternator, AC type ............................................................................................................................................. 24 V, 50 A
Battery ................................................................................................................................................. 2 x 12V, 92 Ah/5 Hr Battery ................................................................................................................................................. 2 x 12V, 92 Ah/5 Hr
Cooling system Cooling system
Fan type............................................................................................ Ø 550 mm (21.65 in), suction type - 8 blades, intake Fan type............................................................................................ Ø 550 mm (21.65 in), suction type - 8 blades, intake
Radiator Radiator
Fin type .................................................................................................................................................................. wavy Fin type .................................................................................................................................................................. wavy
Fin pitch ............................................................................................................................................. 3.5 mm (0.137 in) Fin pitch ............................................................................................................................................. 3.5 mm (0.137 in)
Oil cooler Oil cooler
Fin type .................................................................................................................................................................. wavy Fin type .................................................................................................................................................................. wavy
Fin pitch ............................................................................................................................................. 3.5 mm (0.137 in) Fin pitch ............................................................................................................................................. 3.5 mm (0.137 in)
Inter-cooler Inter-cooler
Fin type ...............................................................................................................................................triangular straight Fin type ...............................................................................................................................................triangular straight
Fin pitch ............................................................................................................................................. 4.0 mm (0.157 in) Fin pitch ............................................................................................................................................. 4.0 mm (0.157 in)
Fuel cooler Fuel cooler
Fin type .................................................................................................................................................................. wavy Fin type .................................................................................................................................................................. wavy
Fin pitch ............................................................................................................................................. 4.0 mm (0.157 in) Fin pitch ............................................................................................................................................. 4.0 mm (0.157 in)
Capacity of coolant and lubricants Capacity of coolant and lubricants
Coolant ..................................................................................................................................................... 14.6 L (3.86 gal) Coolant ..................................................................................................................................................... 14.6 L (3.86 gal)
Fuel ........................................................................................................................................................... 260 L (68.7 gal) Fuel ........................................................................................................................................................... 260 L (68.7 gal)
Lubricant for engine..................................................................................................................................... 17 L (4.49 gal) Lubricant for engine..................................................................................................................................... 17 L (4.49 gal)
Lubricant for travel reduction gear (per side).............................................................................................. 2.1 L (0.55 gal) Lubricant for travel reduction gear (per side).............................................................................................. 2.1 L (0.55 gal)
Lubricant for swing reduction gear (per side) ............................................................................................. 2.2 L (0.58 gal) Lubricant for swing reduction gear (per side) ............................................................................................. 2.2 L (0.58 gal)
Hydraulic oil............................................................................................................................................. 157 L (41.47 gal) Hydraulic oil............................................................................................................................................. 157 L (41.47 gal)
Capacity of hydraulic oil tank..................................................................................................................... 82 L (21.66 gal) Capacity of hydraulic oil tank..................................................................................................................... 82 L (21.66 gal)
Air conditioning Air conditioning
R134 gas load ..............................................................................................................................................1Kg (2.20 Ibs) R134 gas load ..............................................................................................................................................1Kg (2.20 Ibs)
Hydraulic oil filter Hydraulic oil filter
Suction filter (inside tank) ....................................................................................................................................105 mesh Suction filter (inside tank) ....................................................................................................................................105 mesh
Return filter (inside tank) ............................................................................................................................................ 6 µm Return filter (inside tank) ............................................................................................................................................ 6 µm
Pilot line filter (inside housing).................................................................................................................................... 8 µm Pilot line filter (inside housing).................................................................................................................................... 8 µm
Fuel filter Fuel filter
Main filter.................................................................................................................................................................... 4 µm Main filter.................................................................................................................................................................... 4 µm
Pre-filter.................................................................................................................................................................... 10 µm Pre-filter.................................................................................................................................................................... 10 µm
Pre-filter (2PC, 2PC Blade) ........................................................................................................................................ 7 µm Pre-filter (2PC, 2PC Blade) ........................................................................................................................................ 7 µm

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-13 1002-13
Operating devices Operating devices
Operator's seat Operator's seat
Location: left side Location: left side
Structure: Adjustable forward and back and up and down, reclining mechanism, with seat suspension. Structure: Adjustable forward and back and up and down, reclining mechanism, with seat suspension.
Cab Cab
Sealed steel type, all reinforced glass. Sealed steel type, all reinforced glass.
Levers and pedals Levers and pedals
For travel use: Lever and pedal type (hydraulic pilot type) (x2) For travel use: Lever and pedal type (hydraulic pilot type) (x2)
For operating machine use: Lever type (hydraulic pilot type) (x2) For operating machine use: Lever type (hydraulic pilot type) (x2)
For blade operating machine use: Lever type (hydraulic pilot type) (x1); (CX130B (2PC, 2PC Blade)) For blade operating machine use: Lever type (hydraulic pilot type) (x1); (CX130B (2PC, 2PC Blade))
Instruments and switches Instruments and switches
Work mode select switch: 3 modes (SP / super power, H / heavy duty, A / automatic) Work mode select switch: 3 modes (SP / super power, H / heavy duty, A / automatic)
Travel mode select switch: Low-speed / high-speed switch type Travel mode select switch: Low-speed / high-speed switch type
One-touch idle: Knob switch type One-touch idle: Knob switch type
Engine emergency stop: Switch type Engine emergency stop: Switch type
Monitor device Monitor device
Machine status display (full-dot liquid crystal) Machine status display (full-dot liquid crystal)
Work mode selection status: SP / H / A Work mode selection status: SP / H / A
Instruments (full-dot liquid crystal, except for hour meter) Instruments (full-dot liquid crystal, except for hour meter)
Fuel gauge: bar graph indicator Fuel gauge: bar graph indicator
Engine coolant temperature gauge: bar graph indicator Engine coolant temperature gauge: bar graph indicator
Hydraulic oil temperature gauge: bar graph indicator Hydraulic oil temperature gauge: bar graph indicator
Hour meter: digital type Hour meter: digital type
Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm
Over heat* Battery charge* Faulty electrical system* Over heat* Battery charge* Faulty electrical system*
Refill fuel* Engine oil pressure* Refill coolant* Refill fuel* Engine oil pressure* Refill coolant*
Engine preheat Auto warm-up Air cleaner clogged Engine preheat Auto warm-up Air cleaner clogged
Anti-theft device triggered Faulty engine system * Engine emergency stop * Anti-theft device triggered Faulty engine system * Engine emergency stop *

Lighting Lighting
Working light Cab top: 24V, 70W (x1) Working light Cab top: 24V, 70W (x1)
Boom up: 24V, 70W (x1) Boom up: 24V, 70W (x1)
Interior light 24V, 10W (x1) Interior light 24V, 10W (x1)

Horn: electric horn (x2) Horn: electric horn (x2)


Other Other
Wiper with intermittent function, Window washer, Air conditioner, Rear view mirrors (left and right), Clock Wiper with intermittent function, Window washer, Air conditioner, Rear view mirrors (left and right), Clock

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-14 1002-14
Hydraulic system Hydraulic system
Hydraulic pump drive system, directly coupled to the engine (no transmission) Hydraulic pump drive system, directly coupled to the engine (no transmission)
Main pump Main pump
Manufacturer............................................................................................................................................... Kawasaki Manufacturer............................................................................................................................................... Kawasaki
Pump type .............................................................................................. double variable displacement piston pump Pump type .............................................................................................. double variable displacement piston pump
Displacement volume ..................................................................................................... 65 cm3 (3.98 cu in) x 2 /rev Displacement volume ..................................................................................................... 65 cm3 (3.98 cu in) x 2 /rev
Rated operating pressure .......................................................................................................... 34.3 MPa (4975 psi) Rated operating pressure .......................................................................................................... 34.3 MPa (4975 psi)
Maximum operating pressure .................................................................................................... 36.3 MPa (5265 psi) Maximum operating pressure .................................................................................................... 36.3 MPa (5265 psi)
Set pressure of overload relief valve (CX130 2PC): Set pressure of overload relief valve (CX130 2PC):
Boom down, 2nd boom close ................................................................................................. 32.3 Mpa (4684.7 psi) Boom down, 2nd boom close ................................................................................................. 32.3 Mpa (4684.7 psi)
Other....................................................................................................................................... 38.2 Mpa (5540.4 psi) Other....................................................................................................................................... 38.2 Mpa (5540.4 psi)
Input revolution speed.............................................................................................................................. 2000 min-1 Input revolution speed.............................................................................................................................. 2000 min-1
Maximum discharge flow ........................................................................... 130 L/min (34.34 gpm) x 2 at 2000 min-1 Maximum discharge flow ........................................................................... 130 L/min (34.34 gpm) x 2 at 2000 min-1
Pilot pump Pilot pump
Pump type ............................................................................................................................................... Gear pump Pump type ............................................................................................................................................... Gear pump
Displacement volume ............................................................................................................ 10 cm3 (0.61 cu in)/rev Displacement volume ............................................................................................................ 10 cm3 (0.61 cu in)/rev
Operating pressure ...................................................................................................................... 3.92 MPa (568 psi) Operating pressure ...................................................................................................................... 3.92 MPa (568 psi)
Maximum flow ................................................................................................... 20 L/min (5.28 gpm) (at 2000 min-1) Maximum flow ................................................................................................... 20 L/min (5.28 gpm) (at 2000 min-1)
Blade pump Blade pump
Pump type ............................................................................................................................................... Gear pump Pump type ............................................................................................................................................... Gear pump
Displacement volume ......................................................................................................... 28.2 cm3 (1.72 cu in)/rev Displacement volume ......................................................................................................... 28.2 cm3 (1.72 cu in)/rev
Operating pressure .................................................................................................................... 20.6 MPa (2988 psi) Operating pressure .................................................................................................................... 20.6 MPa (2988 psi)
Maximum flow .......................................................................................................................... 59 L/min (15.59 gpm) Maximum flow .......................................................................................................................... 59 L/min (15.59 gpm)
Control method Control method
Hydraulic simultaneous constant output control. Hydraulic simultaneous constant output control.
Maximum flow adjustment control through external commands (negative control). Maximum flow adjustment control through external commands (negative control).
Setting horsepower adjustment control through external command milli-amp. Setting horsepower adjustment control through external command milli-amp.
Control Valve Control Valve
Model; 4-spool section: integrated (1) or 5-spool section: integrated (1) Model; 4-spool section: integrated (1) or 5-spool section: integrated (1)
Operation method: hydraulic pilot method: travel, swing and operating machine Operation method: hydraulic pilot method: travel, swing and operating machine
Maximum flow .................................................................................................130 L / min (34.34 gpm) (at 2000 min-1) Maximum flow .................................................................................................130 L / min (34.34 gpm) (at 2000 min-1)
Main relief set pressure........................................... standard; 34.3 MPa (4975 psi), power boost 36.3 MPa (5265 psi) Main relief set pressure........................................... standard; 34.3 MPa (4975 psi), power boost 36.3 MPa (5265 psi)
Overload set pressure...................................................................................... when boom down; 32.3 MPa (4685 psi) Overload set pressure...................................................................................... when boom down; 32.3 MPa (4685 psi)
.............................................................................................................................................other: 38.2 MPa (5540 psi) .............................................................................................................................................other: 38.2 MPa (5540 psi)
Foot relief set pressure ............................................................................................................... 2.55 MPa (369.85 psi) Foot relief set pressure ............................................................................................................... 2.55 MPa (369.85 psi)
Functions Functions
Straight travel circuit Straight travel circuit
Boom up / arm 2 pumps internal flow Boom up / arm 2 pumps internal flow
Boom and arm load holding circuit Boom and arm load holding circuit
Boom-down regenerative circuit Boom-down regenerative circuit
Bucket-close regenerative circuit Bucket-close regenerative circuit
Arm-in forced regenerative circuit Arm-in forced regenerative circuit
Swing priority variable orifice (for arm operation) Swing priority variable orifice (for arm operation)
2 pumps flow 2 pumps flow

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-15 1002-15
Hydraulic Cylinders Hydraulic Cylinders
Boom cylinder (x2) Boom cylinder (x2)
Cylinder bore ............................................................................................................................. Ø105 mm (Ø4.13 in) Cylinder bore ............................................................................................................................. Ø105 mm (Ø4.13 in)
Rod diametre ............................................................................................................................... Ø70 mm (Ø2.75 in) Rod diametre ............................................................................................................................... Ø70 mm (Ø2.75 in)
Maximum retracted lenght .......................................................................................................... 1464 mm (57.64 in) Maximum retracted lenght .......................................................................................................... 1464 mm (57.64 in)
Stroke ........................................................................................................................................... 961 mm (37.83 in) Stroke ........................................................................................................................................... 961 mm (37.83 in)
Boom cylinder (x2) CX130B (2PC, 2PC Blade) Boom cylinder (x2) CX130B (2PC, 2PC Blade)
Cylinder bore ............................................................................................................................. Ø105 mm (Ø4.13 in) Cylinder bore ............................................................................................................................. Ø105 mm (Ø4.13 in)
Rod diametre ............................................................................................................................... Ø75 mm (Ø2.95 in) Rod diametre ............................................................................................................................... Ø75 mm (Ø2.95 in)
Maximum retracted lenght .......................................................................................................... 1605 mm (63.19 in) Maximum retracted lenght .......................................................................................................... 1605 mm (63.19 in)
Stroke ........................................................................................................................................... 925 mm (36.42 in) Stroke ........................................................................................................................................... 925 mm (36.42 in)
2nd Boom cylinder (x2) CX130B (2PC, 2PC Blade) 2nd Boom cylinder (x2) CX130B (2PC, 2PC Blade)
Cylinder bore ............................................................................................................................. Ø140 mm (Ø5.51 in) Cylinder bore ............................................................................................................................. Ø140 mm (Ø5.51 in)
Rod diametre ............................................................................................................................... Ø90 mm (Ø3.54 in) Rod diametre ............................................................................................................................... Ø90 mm (Ø3.54 in)
Maximum retracted lenght .......................................................................................................... 1385 mm (54.53 in) Maximum retracted lenght .......................................................................................................... 1385 mm (54.53 in)
Stroke ........................................................................................................................................... 840 mm (33.07 in) Stroke ........................................................................................................................................... 840 mm (33.07 in)
Arm (dipper) cylinder Arm (dipper) cylinder
Cylinder bore ............................................................................................................................. Ø115 mm (Ø4.53 in) Cylinder bore ............................................................................................................................. Ø115 mm (Ø4.53 in)
Rod diametre ............................................................................................................................... Ø80 mm (Ø3.15 in) Rod diametre ............................................................................................................................... Ø80 mm (Ø3.15 in)
Maximum retracted lenght .......................................................................................................... 1619 mm (63.74 in) Maximum retracted lenght .......................................................................................................... 1619 mm (63.74 in)
Stroke ......................................................................................................................................... 1108 mm (43.62 in) Stroke ......................................................................................................................................... 1108 mm (43.62 in)
Bucket cylinder Bucket cylinder
Cylinder bore ............................................................................................................................... Ø95 mm (Ø3.74 in) Cylinder bore ............................................................................................................................... Ø95 mm (Ø3.74 in)
Rod diametre ............................................................................................................................... Ø65 mm (Ø2.56 in) Rod diametre ............................................................................................................................... Ø65 mm (Ø2.56 in)
Maximum retracted lenght .......................................................................................................... 1373 mm (54.05 in) Maximum retracted lenght .......................................................................................................... 1373 mm (54.05 in)
Stroke ........................................................................................................................................... 881 mm (34.68 in) Stroke ........................................................................................................................................... 881 mm (34.68 in)
Blade cylinder Blade cylinder
Cylinder bore ............................................................................................................................. Ø100 mm (Ø3.94 in) Cylinder bore ............................................................................................................................. Ø100 mm (Ø3.94 in)
Rod diametre ............................................................................................................................... Ø70 mm (Ø2.75 in) Rod diametre ............................................................................................................................... Ø70 mm (Ø2.75 in)
Maximum retracted lenght ............................................................................................................ 590 mm (23.23 in) Maximum retracted lenght ............................................................................................................ 590 mm (23.23 in)
Stroke ............................................................................................................................................. 203 mm (7.99 in) Stroke ............................................................................................................................................. 203 mm (7.99 in)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-16 1002-16
Rotating Joint Rotating Joint
Operating pressure Operating pressure
High pressure passage (ABCD) ............................................................................................... 34.3 MPa (4975 psi) High pressure passage (ABCD) ............................................................................................... 34.3 MPa (4975 psi)
High pressure passage (EF) (CX130B Blade).......................................................................... 20.6 MPa (2988 psi) High pressure passage (EF) (CX130B Blade).......................................................................... 20.6 MPa (2988 psi)
Drain port (E) .............................................................................................................................. 0.5 MPa (72.52 psi) Drain port (E) .............................................................................................................................. 0.5 MPa (72.52 psi)
Drain port (G) (CX130B Blade)................................................................................................... 0.5 MPa (72.52 psi) Drain port (G) (CX130B Blade)................................................................................................... 0.5 MPa (72.52 psi)
Pilot port (F)................................................................................................................................... 3.9 MPa (566 psi) Pilot port (F)................................................................................................................................... 3.9 MPa (566 psi)
Pilot port (H) (CX130 Blade).......................................................................................................... 3.9 MPa (566 psi) Pilot port (H) (CX130 Blade).......................................................................................................... 3.9 MPa (566 psi)
Flow Flow
High pressure passage (ABCD) ............................................................................................ 234 L/min (61.82 gpm) High pressure passage (ABCD) ............................................................................................ 234 L/min (61.82 gpm)
High pressure passage (ABCD) (CX130B Blade) ................................................................. 210 L/min (55.48 gpm) High pressure passage (ABCD) (CX130B Blade) ................................................................. 210 L/min (55.48 gpm)
High pressure passage (EF) (CX130B Blade)...................................................................... 80.5 L/min (21.27 gpm) High pressure passage (EF) (CX130B Blade)...................................................................... 80.5 L/min (21.27 gpm)
Drain port (E) ............................................................................................................................. 10 L/min (2.64 gpm) Drain port (E) ............................................................................................................................. 10 L/min (2.64 gpm)
Drain port (G) (CX130B Blade).................................................................................................. 10 L/min (2.64 gpm) Drain port (G) (CX130B Blade).................................................................................................. 10 L/min (2.64 gpm)
Pilot port (F)............................................................................................................................... 21 L/min (5.55 gpm) Pilot port (F)............................................................................................................................... 21 L/min (5.55 gpm)
Pilot port (H) (CX130B Blade) ................................................................................................ 19.8 L/min (5.23 gpm) Pilot port (H) (CX130B Blade) ................................................................................................ 19.8 L/min (5.23 gpm)

Port A; forward right ................................................................................................................................................G3/4 Port A; forward right ................................................................................................................................................G3/4


Port B; forward left ..................................................................................................................................................G3/4 Port B; forward left ..................................................................................................................................................G3/4
Port C; backward right.............................................................................................................................................G3/4 Port C; backward right.............................................................................................................................................G3/4
Port D; backward left ...............................................................................................................................................G3/4 Port D; backward left ...............................................................................................................................................G3/4
Port E; drain port ....................................................................................................................................................G1/2 Port E; drain port ....................................................................................................................................................G1/2
Port E; blade up (CX130B Blade) .......................................................................................................................... G1/2 Port E; blade up (CX130B Blade) .......................................................................................................................... G1/2
Port F; pilot port .....................................................................................................................................................G1/4 Port F; pilot port .....................................................................................................................................................G1/4
Port F; blade down (CX130B Blade) .......................................................................................................................G1/2 Port F; blade down (CX130B Blade) .......................................................................................................................G1/2
Port G; drain port (CX130B Blade) .........................................................................................................................G1/2 Port G; drain port (CX130B Blade) .........................................................................................................................G1/2
Port H; pilot port (CX130B Blade) ...........................................................................................................................G1/4 Port H; pilot port (CX130B Blade) ...........................................................................................................................G1/4

Solenoid Valve Solenoid Valve


Maximum flow ..........................................................................P -> B: 25 L/min (6.60 gpm) Other: 5 L/min (1.32 gpm) Maximum flow ..........................................................................P -> B: 25 L/min (6.60 gpm) Other: 5 L/min (1.32 gpm)
Rated pressure ............................................................................................................................. 4.5 MPa (652.67 psi) Rated pressure ............................................................................................................................. 4.5 MPa (652.67 psi)
Port size Port size
P, T, B port...........................................................................................................................................................G3/8 P, T, B port...........................................................................................................................................................G3/8
C1, C2, C3, C4, C5 port .....................................................................................................................................G1/4 C1, C2, C3, C4, C5 port .....................................................................................................................................G1/4
Solenoid specifications Solenoid specifications
Operating voltage ................................................................................................................................DC 20 to 32 V Operating voltage ................................................................................................................................DC 20 to 32 V
Power consumption .................................................................................................................................. 17 W max. Power consumption .................................................................................................................................. 17 W max.

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-17 1002-17
Hand control valve Hand control valve
Manufacturer................................................................................................................................................... Kawasaki Manufacturer................................................................................................................................................... Kawasaki
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type .......................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi) Secondary pressure, primary short type .......................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi)
Operating angle Operating angle
Ports 1, 3 .............................................................................................................................................................. 19° Ports 1, 3 .............................................................................................................................................................. 19°
Ports 2, 4 .............................................................................................................................................................. 25° Ports 2, 4 .............................................................................................................................................................. 25°

Port 1, 3 Port 2, 4 Port 1, 3 Port 2, 4


4.0 4.0 4.0 4.0
Secondary Secondary
Secondary pressure (MPa)

Secondary pressure (MPa)


pressure pressure

Secondary pressure (MPa)

Secondary pressure (MPa)


3.0 3.0 3.0 3.0

2.0 2.0 2.0 2.0

1.0 1.0 1.0 1.0


Secondary Secondary
pressure pressure
0 0 0 0
2 4 6 7 2 4 6 8 9.4 2 4 6 7 2 4 6 8 9.4
Push rod stroke (mm) Push rod stroke (mm) Push rod stroke (mm) Push rod stroke (mm)

0 5 10 15 19 0 5 10 15 20 25 0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.) Operating angle (deg.) Operating angle (deg.)

RST-03-01-001B RST-03-01-001B

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-18 1002-18
Foot control valve Foot control valve
Manufacturer ................................................................................................................................................... Kawasaki Manufacturer ................................................................................................................................................... Kawasaki
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type........................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi) Secondary pressure, primary short type........................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi)
Operating angle...................................................................................................................................................... 12.4° Operating angle...................................................................................................................................................... 12.4°

3.9 3.9

Secondary pressure (MPa)

Secondary pressure (MPa)


3.0 3.0

2.0 2.0

1.0 1.0
Secondary Secondary
pressure pressure
0 0
2 4 5.5 2 4 5.5
Push rod stroke (mm) Push rod stroke (mm)

0 5 10 12.4 0 5 10 12.4
Operating angle (deg.) Operating angle (deg.)

RST-03-01-001D RST-03-01-001D

For blade valve For blade valve


Manufacturer ................................................................................................................................. Nishina industry., Ltd Manufacturer ................................................................................................................................. Nishina industry., Ltd
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type........................................................... 0.59 to 3.14 MPa (85.57 to 455.42 psi) Secondary pressure, primary short type........................................................... 0.59 to 3.14 MPa (85.57 to 455.42 psi)
Operating angle......................................................................................................................................................... 10° Operating angle......................................................................................................................................................... 10°

4.0 4.0
Secondary pressure (MPa)

Secondary pressure (MPa)


3.0 3.0
Secondary Secondary
pressure pressure
2.0 2.0

1.0 1.0

0 0
2 4 6 8 10 2 4 6 8 10
Push rod stroke (mm) Push rod stroke (mm)

0 0.66 1.32 1.98 2.64 3.30 0 0.66 1.32 1.98 2.64 3.30
Operating angle (deg.) Operating angle (deg.)
NR05001-001 NR05001-001

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-19 1002-19
Swing unit Swing unit
Swing circle ........................................................................................................... Swing bearing type (with internal gear) Swing circle ........................................................................................................... Swing bearing type (with internal gear)
Swing parking brake................................................................................ Mechanical lock (operational lever linkage type) Swing parking brake................................................................................ Mechanical lock (operational lever linkage type)
Swing hydraulic motor ..................................................................................................... Fixed displacement piston motor Swing hydraulic motor ..................................................................................................... Fixed displacement piston motor
Displacement ............................................................................................................................. 65 cm3 (3.97 cu in)/rev Displacement ............................................................................................................................. 65 cm3 (3.97 cu in)/rev
Operating pressure ........................................................................................................................ 27.9 MPa (4046 psi) Operating pressure ........................................................................................................................ 27.9 MPa (4046 psi)
Operating flow............................................................................................................................. 130 L/min(34.34 gpm) Operating flow............................................................................................................................. 130 L/min(34.34 gpm)
Mechanical brake torque ................................................................................................... 336.1 Nm (243.89 lb-ft) min. Mechanical brake torque ................................................................................................... 336.1 Nm (243.89 lb-ft) min.
Brake off pressure ................................................................................................................2.9 MPa (420.61 psi) max. Brake off pressure ................................................................................................................2.9 MPa (420.61 psi) max.
Relief valve set pressure .......................................................................................................27.9 MPa (4046 psi) max. Relief valve set pressure .......................................................................................................27.9 MPa (4046 psi) max.
Reduction gear....................................................................................................... Planetary gear 2-stage reduction gear Reduction gear....................................................................................................... Planetary gear 2-stage reduction gear
Reduction ratio.......................................................................................................................................................17.03 Reduction ratio.......................................................................................................................................................17.03
Travel lower body Travel lower body
Travel hydraulic motor (x2) ......... Variable displacement piston motor, automatic 2-speed switch-over with parking brake Travel hydraulic motor (x2) ......... Variable displacement piston motor, automatic 2-speed switch-over with parking brake
Displacement ...........................................................................................................44.9/74.3 cm3 (2.74/4.53 cu in)/rev Displacement ...........................................................................................................44.9/74.3 cm3 (2.74/4.53 cu in)/rev
Operating pressure ........................................................................................................................ 34.3 MPa (4975 psi) Operating pressure ........................................................................................................................ 34.3 MPa (4975 psi)
Operating flow............................................................................................................................ 130 L/min (34.34 gpm) Operating flow............................................................................................................................ 130 L/min (34.34 gpm)
Brake torque ........................................................................11.1 KNm (8186.9 Ib-ft) min. (including reduction gear) Brake torque ........................................................................11.1 KNm (8186.9 Ib-ft) min. (including reduction gear)
Relief valve set pressure................................................................................................................ 37.3 MPa (5410 psi) Relief valve set pressure................................................................................................................ 37.3 MPa (5410 psi)
Automatic 2-speed switch-over pressure...................................................... 25 to 27 MPa (3625.94 to 3916.01 psi) Automatic 2-speed switch-over pressure...................................................... 25 to 27 MPa (3625.94 to 3916.01 psi)
Reduction gear....................................................................................................... Planetary gear 2-stage reduction gear Reduction gear....................................................................................................... Planetary gear 2-stage reduction gear
Reduction ratio............................................................................................................................................................54 Reduction ratio............................................................................................................................................................54
Travel brake.................................................................................................................................................. Hydraulic lock Travel brake.................................................................................................................................................. Hydraulic lock
Parking brake ................................................................................................... Mechanical lock (travel lever linkage type) Parking brake ................................................................................................... Mechanical lock (travel lever linkage type)
Track shoe Track shoe
Model ........................................................................................................................Assembly type triple grouser shoe Model ........................................................................................................................Assembly type triple grouser shoe
Number of shoes (per side) Number of shoes (per side)
CX130B ..................................................................................................................................................................43 CX130B ..................................................................................................................................................................43
CX130B (LC) ..........................................................................................................................................................46 CX130B (LC) ..........................................................................................................................................................46
CX130B (Blade) .....................................................................................................................................................43 CX130B (Blade) .....................................................................................................................................................43
Shoe width Shoe width
Standard ....................................................................................................................................... 600 mm (23.62 in) Standard ....................................................................................................................................... 600 mm (23.62 in)
Optional ..................................................................................................... 500 mm (19.68 in); 700 mm (27.55 mm) Optional ..................................................................................................... 500 mm (19.68 in); 700 mm (27.55 mm)
Grouser height ...................................................................................................................................... 20 mm (0.79 in) Grouser height ...................................................................................................................................... 20 mm (0.79 in)
Link pitch.......................................................................................................................................... 171.5 mm (6.75 in) Link pitch.......................................................................................................................................... 171.5 mm (6.75 in)
Roller Roller
Number of upper rollers (per side) (CX130B; CX130B (2PC)) .....................................................................................1 Number of upper rollers (per side) (CX130B; CX130B (2PC)) .....................................................................................1
Number of upper rollers (per side) (CX130B LC) .........................................................................................................2 Number of upper rollers (per side) (CX130B LC) .........................................................................................................2
Number of upper rollers (per side) (CX130B Blade; CX130B (2PC Blade)).................................................................1 Number of upper rollers (per side) (CX130B Blade; CX130B (2PC Blade)).................................................................1
Number of lower rollers (per side) ................................................................................................................................7 Number of lower rollers (per side) ................................................................................................................................7
Track belt tension adjuster ...............................................................................Grease cylinder type (with cushion spring) Track belt tension adjuster ...............................................................................Grease cylinder type (with cushion spring)
Mounting length of spring...................................................................................................................... 419 mm (16.50 in) Mounting length of spring...................................................................................................................... 419 mm (16.50 in)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-20 1002-20
Work Unit Work Unit
Model..................................................................................................................................................Backhoe attachment Model..................................................................................................................................................Backhoe attachment
Components / dimensions / working dimensions Components / dimensions / working dimensions

CX130B/CX130B(LC)/CX130B(Blade) CX130B/CX130B(LC)/CX130B(Blade)

CX130B (Standard boom) Standard arm Short arm Long arm CX130B (Standard boom) Standard arm Short arm Long arm
2500 mm 2110 mm 3010 mm 2500 mm 2110 mm 3010 mm
(98.42 in) (83.07 in) (118.50 in) (98.42 in) (83.07 in) (118.50 in)
3086 mm 2690 mm 3605 mm 3086 mm 2690 mm 3605 mm
Arm (dipper) length Arm (dipper) length
(121.50 in) (105.91 in) (141.93 in) (121.50 in) (105.91 in) (141.93 in)
4630 mm 4630 mm
Boom length (Standard boom spec.) Boom length (Standard boom spec.)
182.28 in 182.28 in
1200 mm 1200 mm
Bucket radius Bucket radius
47.24 in 47.24 in
Bucket wrist action 178° Bucket wrist action 178°
8310 mm 7690 mm 8770 mm 8310 mm 7690 mm 8770 mm
Maximum digging radius Maximum digging radius
327.16 in 302.75 in 345.27 in 327.16 in 302.75 in 345.27 in
8170 mm 7810 mm 8640 mm 8170 mm 7810 mm 8640 mm
Maximum digging radius at ground line Maximum digging radius at ground line
321.65 in 307.48 in 340.16 in 321.65 in 307.48 in 340.16 in
5540 mm 5150 mm 6050 mm 5540 mm 5150 mm 6050 mm
Maximum digging depth Maximum digging depth
218.11 in 202.75 in 238.19 in 218.11 in 202.75 in 238.19 in
4950 mm 4600 mm 5350 mm 4950 mm 4600 mm 5350 mm
Maximum vertical straight wall digging depth Maximum vertical straight wall digging depth
194.88 in 181.10 in 210.63 in 194.88 in 181.10 in 210.63 in
8770 mm 8550 mm 9050 mm 8770 mm 8550 mm 9050 mm
Maximum digging height Maximum digging height
345.27 in 336.61 in 356.30 in 345.27 in 336.61 in 356.30 in
6390 mm 6170 mm 6680 mm 6390 mm 6170 mm 6680 mm
Maximum dump height Maximum dump height
251.57 in 242.91 in 262.99 in 251.57 in 242.91 in 262.99 in
2340 mm 2360 mm 2660 mm 2340 mm 2360 mm 2660 mm
Minimum swing radius at front Minimum swing radius at front
92.13 in 92.91 in 104.72 in 92.13 in 92.91 in 104.72 in
6560 mm 6560 mm 6590 mm 6560 mm 6560 mm 6590 mm
Height for minimum swing radius at front Height for minimum swing radius at front
258.27 in 258.27 in 259.45 in 258.27 in 258.27 in 259.45 in

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-21 1002-21

CX130B (2PC)/CX130B (2PC Blade) CX130B (2PC)/CX130B (2PC Blade)

CX130B (2PC) Standard arm Short arm Long arm CX130B (2PC) Standard arm Short arm Long arm
2500 mm 2110 mm 3010 mm 2500 mm 2110 mm 3010 mm
(98.42 in) (83.07 in) (118.50 in) (98.42 in) (83.07 in) (118.50 in)
3086 mm 2690 mm 3605 mm 3086 mm 2690 mm 3605 mm
Arm (dipper) length Arm (dipper) length
(121.50 in) (105.91 in) (141.93 in) (121.50 in) (105.91 in) (141.93 in)
4630 mm 4630 mm
Boom length (Standard boom spec.) Boom length (Standard boom spec.)
182.28 in 182.28 in
1200 mm 1200 mm
Bucket radius Bucket radius
47.24 in 47.24 in
8440 mm 8090 mm 8910 mm 8440 mm 8090 mm 8910 mm
Maximum digging radius Maximum digging radius
332.28 in 319.50 in 350.78 in 332.28 in 319.50 in 350.78 in
8300 mm 7940 mm 8790 mm 8300 mm 7940 mm 8790 mm
Maximum digging radius at ground line Maximum digging radius at ground line
326.77 in 312.60 in 346.06 in 326.77 in 312.60 in 346.06 in
5390 mm 5010 mm 5900 mm 5390 mm 5010 mm 5900 mm
Maximum digging depth Maximum digging depth
212.20 in 197.24 in 232.28 in 212.20 in 197.24 in 232.28 in
4150 mm 3370 mm 4630 mm 4150 mm 3370 mm 4630 mm
Maximum vertical straight wall digging depth Maximum vertical straight wall digging depth
163.38 in 132.68 in 182.28 in 163.38 in 132.68 in 182.28 in
9320 mm 9050 mm 9680 mm 9320 mm 9050 mm 9680 mm
Maximum digging height Maximum digging height
366.93 in 356.30 in 381.10 in 366.93 in 356.30 in 381.10 in
6920 mm 6550 mm 7280 mm 6920 mm 6550 mm 7280 mm
Maximum dump height Maximum dump height
272.44 in 257.87 in 281.61 in 272.44 in 257.87 in 281.61 in
2150 mm 2160 mm 2370 mm 2150 mm 2160 mm 2370 mm
Minimum swing radius at front Minimum swing radius at front
84.64 in 85.04 in 93.31 in 84.64 in 85.04 in 93.31 in
6840 mm 6840 mm 6870 mm 6840 mm 6840 mm 6870 mm
Height for minimum swing radius at front Height for minimum swing radius at front
269.29 in 269.29 in 270.47 in 269.29 in 269.29 in 270.47 in

Digging force (ISO 6015) Digging force (ISO 6015)


Arm (dipper) CX130B/CX130B(LC)/CX130B(Blade) Arm (dipper) CX130B/CX130B(LC)/CX130B(Blade)
2500 mm 3010 mm 2110 mm 2500 mm 3010 mm 2110 mm
(98.42 in) (118.50 in) (83.07 in) (98.42 in) (118.50 in) (83.07 in)
62 kN 56 kN 70 kN 62 kN 56 kN 70 kN
Arm (dipper) digging force (standard) Arm (dipper) digging force (standard)
(13938.15 lbf) (12589.3 lbf) (15736.63 lbf) (13938.15 lbf) (12589.3 lbf) (15736.63 lbf)
66 kN 60 KN 74 kN 66 kN 60 KN 74 kN
Arm (dipper) digging force (power up) Arm (dipper) digging force (power up)
(14837.39 lbf) (13488.54 lbf) (16635.86 lbf) (14837.39 lbf) (13488.54 lbf) (16635.86 lbf)
90 kN 90 kN 90 kN 90 kN 90 kN 90 kN
Bucket digging force (standard) Bucket digging force (standard)
(20232.8 lbf) (20232.8 lbf) (20232.8 lbf) (20232.8 lbf) (20232.8 lbf) (20232.8 lbf)
95 kN 95 kN 95 kN 95 kN 95 kN 95 kN
Bucket digging force (power up) Bucket digging force (power up)
(21356.85 lbf) (21356.85 lbf) (21356.85 lbf) (21356.85 lbf) (21356.85 lbf) (21356.85 lbf)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-22 1002-22
COMPONENT WEIGHT COMPONENT WEIGHT
Major component weight (CX130B) Major component weight (CX130B)

B B
A A

C C

E E

D D

F H F H
G G

RST-11-01-001A RST-11-01-001A
Weight information is approximate Weight information is approximate
A) Operating weight ......................................................................................................................12300 kg (27117 lbs) A) Operating weight ......................................................................................................................12300 kg (27117 lbs)
B) Upper mechanism (including counterweight and turntable bearing) ..........................................5960 kg (13139 lbs) B) Upper mechanism (including counterweight and turntable bearing) ..........................................5960 kg (13139 lbs)
C) Counterweight ..............................................................................................................................2290 kg (5049 lbs) C) Counterweight ..............................................................................................................................2290 kg (5049 lbs)
D) Lower mechanism (with standard grouser shoe) .........................................................................4150 kg (9149 lbs) D) Lower mechanism (with standard grouser shoe) .........................................................................4150 kg (9149 lbs)
E) Main Unit Weight ......................................................................................................................10110 kg (22289 lbs) E) Main Unit Weight ......................................................................................................................10110 kg (22289 lbs)
F) Attachments..................................................................................................................................2190 kg (4828 lbs) F) Attachments..................................................................................................................................2190 kg (4828 lbs)
G) Boom (including cylinders) ...........................................................................................................1220 kg (2690 lbs) G) Boom (including cylinders) ...........................................................................................................1220 kg (2690 lbs)
H) Arm (dipper) (including cylinders and linkage) ...............................................................................570 kg (1253 lbs) H) Arm (dipper) (including cylinders and linkage) ...............................................................................570 kg (1253 lbs)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-23 1002-23
COMPONENT WEIGHT COMPONENT WEIGHT
Major component weight (CX130B 2PC, CX130B 2PC (with Blade)) Major component weight (CX130B 2PC, CX130B 2PC (with Blade))

CX130B 2PC CX130B 2PC


Sym Component name CX130B 2PC Sym Component name CX130B 2PC
(with Blade) (with Blade)
A Operating weight 13200 Kg (29101 lbs) 14000 Kg (30865 lbs) A Operating weight 13200 Kg (29101 lbs) 14000 Kg (30865 lbs)
Upper component Upper component
B 6150 Kg (13558 lbs) 6190 Kg (13647 lbs) B 6150 Kg (13558 lbs) 6190 Kg (13647 lbs)
(including counterweight and turntable bearing) (including counterweight and turntable bearing)
C Counterweight 2190 Kg (48.28 lbs) 2190 Kg (4828 lbs) C Counterweight 2190 Kg (48.28 lbs) 2190 Kg (4828 lbs)
D Lower component (with grouser shoe) 4170 Kg (9193 lbs) 4930 Kg (10869 lbs) D Lower component (with grouser shoe) 4170 Kg (9193 lbs) 4930 Kg (10869 lbs)
E Main unit weight 10340 Kg (22796 lbs) 11130 Kg (24537 lbs) E Main unit weight 10340 Kg (22796 lbs) 11130 Kg (24537 lbs)
F Attachments 2600 Kg (5732 lbs) 2800 Kg (6173 lbs) F Attachments 2600 Kg (5732 lbs) 2800 Kg (6173 lbs)
G Boom (including cylinders) 1800 Kg (3968 lbs) 1800 Kg (3968 lbs) G Boom (including cylinders) 1800 Kg (3968 lbs) 1800 Kg (3968 lbs)
H Arm (including cylinders and linkage) 600 Kg (1323 lbs) 600 Kg (1323 lbs) H Arm (including cylinders and linkage) 600 Kg (1323 lbs) 600 Kg (1323 lbs)
I Blade - 610 Kg (1345 lbs) I Blade - 610 Kg (1345 lbs)

* The weights displayed are approximate weights. * The weights displayed are approximate weights.

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-24 1002-24
Other component weight Other component weight
Engine ....................................................................................................................................................328 kg (723.1 lbs) Engine ....................................................................................................................................................328 kg (723.1 lbs)
Air cleaner .................................................................................................................................................5.4 kg (11.9 lbs) Air cleaner .................................................................................................................................................5.4 kg (11.9 lbs)
Hydraulic pump ........................................................................................................................................81 kg (178.6 lbs) Hydraulic pump ........................................................................................................................................81 kg (178.6 lbs)
Blade pump .................................................................................................................................................4.4 kg (9.7 lbs) Blade pump .................................................................................................................................................4.4 kg (9.7 lbs)
Hydraulic pump (CX130B 2PC with Blade) ..............................................................................................90 kg (198.4 lbs) Hydraulic pump (CX130B 2PC with Blade) ..............................................................................................90 kg (198.4 lbs)
Attachment control valve Attachment control valve
CX130B, CX130B (LC) standard boom ............................................................................................160 kg (352.7 lbs) CX130B, CX130B (LC) standard boom ............................................................................................160 kg (352.7 lbs)
CX130B (Blade) ....................................................................................................................................176 kg (388 lbs) CX130B (Blade) ....................................................................................................................................176 kg (388 lbs)
CX130B 2PC......................................................................................................................................174 kg (383.6 lbs) CX130B 2PC......................................................................................................................................174 kg (383.6 lbs)
CX130B 2PC (with Blade).....................................................................................................................183 kg (410 lbs) CX130B 2PC (with Blade).....................................................................................................................183 kg (410 lbs)
Swing unit.................................................................................................................................................99 kg (218.3 lbs) Swing unit.................................................................................................................................................99 kg (218.3 lbs)
Travel unit ...............................................................................................................................................145 kg (319.7 lbs) Travel unit ...............................................................................................................................................145 kg (319.7 lbs)
Rotary joint Rotary joint
CX130B, (CX130B LC), (CX 130B 2PC)................................................................................................29.5 kg (65 lbs) CX130B, (CX130B LC), (CX 130B 2PC)................................................................................................29.5 kg (65 lbs)
CX130B (Blade), (CX130B 2PC (with Blade)) ..................................................................................53.4 kg (117.7 lbs) CX130B (Blade), (CX130B 2PC (with Blade)) ..................................................................................53.4 kg (117.7 lbs)
Solenoid valve (4 stack) ..................................................................................................................................5 kg (11 lbs) Solenoid valve (4 stack) ..................................................................................................................................5 kg (11 lbs)
Cushion valve ..........................................................................................................................................12.5 kg (27.6 lbs) Cushion valve ..........................................................................................................................................12.5 kg (27.6 lbs)
Hand control valve.....................................................................................................................................1.9 kg (4.18 lbs) Hand control valve.....................................................................................................................................1.9 kg (4.18 lbs)
Foot control valve ......................................................................................................................................7.8 kg (17.1 lbs) Foot control valve ......................................................................................................................................7.8 kg (17.1 lbs)
Standard boom.....................................................................................................................................718 kg (1582.9 lbs) Standard boom.....................................................................................................................................718 kg (1582.9 lbs)
Standard arm (dipper) ............................................................................................................................360 kg (793.7 lbs) Standard arm (dipper) ............................................................................................................................360 kg (793.7 lbs)
Short arm (dipper) ..................................................................................................................................317 kg (698.9 lbs) Short arm (dipper) ..................................................................................................................................317 kg (698.9 lbs)
Long arm (dipper)...................................................................................................................................437 kg (963.4 lbs) Long arm (dipper)...................................................................................................................................437 kg (963.4 lbs)
Boom (CX130B 2PC, CX130B 2PC (with Blade)) ..............................................................................1122 kg (2473.6 lbs) Boom (CX130B 2PC, CX130B 2PC (with Blade)) ..............................................................................1122 kg (2473.6 lbs)
Fuel tank......................................................................................................................................................84 kg (185 lbs) Fuel tank......................................................................................................................................................84 kg (185 lbs)
Hydraulic oil tank ......................................................................................................................................95 kg (209.4 lbs) Hydraulic oil tank ......................................................................................................................................95 kg (209.4 lbs)
Turntable bearing.......................................................................................................................................178 kg (388 lbs) Turntable bearing.......................................................................................................................................178 kg (388 lbs)
Muffler .....................................................................................................................................................13.5 kg (29.8 lbs) Muffler .....................................................................................................................................................13.5 kg (29.8 lbs)
Radiator total weight.................................................................................................................................73 kg (160.9 lbs) Radiator total weight.................................................................................................................................73 kg (160.9 lbs)
Idler wheel ...........................................................................................................................................65.2 kg (143.74 lbs) Idler wheel ...........................................................................................................................................65.2 kg (143.74 lbs)
Upper roller..............................................................................................................................................15.6 kg (34.3 lbs) Upper roller..............................................................................................................................................15.6 kg (34.3 lbs)
Lower roller..............................................................................................................................................21.4 kg (47.1 lbs) Lower roller..............................................................................................................................................21.4 kg (47.1 lbs)
Lower roller (CX130B 2PC, CX130B 2PC (with Blade)).............................................................................26 kg (57.3 lbs) Lower roller (CX130B 2PC, CX130B 2PC (with Blade)).............................................................................26 kg (57.3 lbs)
Recoil spring assembly ............................................................................................................................78 kg (171.9 lbs) Recoil spring assembly ............................................................................................................................78 kg (171.9 lbs)
Recoil spring .......................................................................................................................................31.7 kg (69.9 lbs) Recoil spring .......................................................................................................................................31.7 kg (69.9 lbs)
Grease cylinder assembly...................................................................................................................14.6 kg (32.2 lbs) Grease cylinder assembly...................................................................................................................14.6 kg (32.2 lbs)
Threaded rod ......................................................................................................................................15.2 kg (33.5 lbs) Threaded rod ......................................................................................................................................15.2 kg (33.5 lbs)
Yoke ....................................................................................................................................................15.1 kg (33.3 lbs) Yoke ....................................................................................................................................................15.1 kg (33.3 lbs)
Track chains (per side) Track chains (per side)
500 mm (19.68 in) ............................................................................................................................710 kg (1565.3 lbs) 500 mm (19.68 in) ............................................................................................................................710 kg (1565.3 lbs)
600 mm (23.62 in) ............................................................................................................................800 kg (1763.7 lbs) 600 mm (23.62 in) ............................................................................................................................800 kg (1763.7 lbs)
700 mm (27.56 in) ............................................................................................................................950 kg (2094.4 lbs) 700 mm (27.56 in) ............................................................................................................................950 kg (2094.4 lbs)
Cylinder Cylinder
Boom cylinder .......................................................................................................................................108 kg (238 lbs) Boom cylinder .......................................................................................................................................108 kg (238 lbs)
Boom cylinder (2PC; 2PC blade) .......................................................................................................107 kg (235.8 lbs) Boom cylinder (2PC; 2PC blade) .......................................................................................................107 kg (235.8 lbs)
2nd boom cylinder (2PC; 2PC blade).................................................................................................184 kg (405.6 lbs) 2nd boom cylinder (2PC; 2PC blade).................................................................................................184 kg (405.6 lbs)
Arm cylinder .......................................................................................................................................156 kg (343.9 lbs) Arm cylinder .......................................................................................................................................156 kg (343.9 lbs)
Arm cylinder (2PC; 2PC blade) ..........................................................................................................153 kg (337.3 lbs) Arm cylinder (2PC; 2PC blade) ..........................................................................................................153 kg (337.3 lbs)
Bucket cylinder.....................................................................................................................................91 kg (200.6 lbs) Bucket cylinder.....................................................................................................................................91 kg (200.6 lbs)
Blade cylinder ........................................................................................................................................45 kg (99.2 lbs) Blade cylinder ........................................................................................................................................45 kg (99.2 lbs)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-25 1002-25
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY
Sprocket Sprocket

a p a p

d
b

b
c

c
RI14001-001 RI14001-001

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
a 59 53 Acceptable/Unacceptable a 59 53 Acceptable/Unacceptable
b Ø Ø584.48 Ø578.5 Acceptable/Unacceptable b Ø Ø584.48 Ø578.5 Acceptable/Unacceptable
Cladding by welding Cladding by welding
Sprocket c Ø Ø652 Ø646 Acceptable/Unacceptable Sprocket c Ø Ø652 Ø646 Acceptable/Unacceptable
or replacement or replacement
d Ø Ø635.48 - Acceptable/Unacceptable d Ø Ø635.48 - Acceptable/Unacceptable
p 171.45 - Acceptable/Unacceptable p 171.45 - Acceptable/Unacceptable

Gauge Gauge
unit in mm unit in mm

NI14002-008 NI14002-008

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-26 1002-26
Idler wheel Idler wheel

b
c c
a

a
e f e f
d

d
RI14001-002 RI14001-002

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
b 17.5 - Acceptable/Unacceptable b 17.5 - Acceptable/Unacceptable
Cladding by welding Cladding by welding
Ilder wheel a Ø Ø510 Ø506 Acceptable/Unacceptable Ilder wheel a Ø Ø510 Ø506 Acceptable/Unacceptable
or replacement or replacement
c 68 64 Acceptable/Unacceptable c 68 64 Acceptable/Unacceptable
Shaft d Ø Ø55 Ø54.5 Acceptable/Unacceptable Replacement Shaft d Ø Ø55 Ø54.5 Acceptable/Unacceptable Replacement
d Ø Ø55 Ø55.8 Acceptable/Unacceptable d Ø Ø55 Ø55.8 Acceptable/Unacceptable
Bushing Replacement Bushing Replacement
e 55 54.6 Acceptable/Unacceptable e 55 54.6 Acceptable/Unacceptable
Hub f 19.9 20.4 Acceptable/Unacceptable Replacement Hub f 19.9 20.4 Acceptable/Unacceptable Replacement

Gauge Gauge
unit in mm unit in mm

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-27 1002-27
Upper roller Upper roller
f f
g e g e

a
d

d
b

b
c c
RI14001-003 RI14001-003

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
a Ø Ø120 Ø112 Acceptable/Unacceptable a Ø Ø120 Ø112 Acceptable/Unacceptable
Cladding by welding Cladding by welding
Carrier roller b 10 - Acceptable/Unacceptable Carrier roller b 10 - Acceptable/Unacceptable
or replacement or replacement
c 68 62 Acceptable/Unacceptable c 68 62 Acceptable/Unacceptable
Shaft d Ø Ø40 Ø39.5 Acceptable/Unacceptable Replacement Shaft d Ø Ø40 Ø39.5 Acceptable/Unacceptable Replacement
d Ø Ø40 Ø40.8 Acceptable/Unacceptable d Ø Ø40 Ø40.8 Acceptable/Unacceptable
Bushing Replacement Bushing Replacement
e 63 62.6 Acceptable/Unacceptable e 63 62.6 Acceptable/Unacceptable
Thrust plate f 5.5 5 Acceptable/Unacceptable Replacement Thrust plate f 5.5 5 Acceptable/Unacceptable Replacement
Cover g 22.5 22 Acceptable/Unacceptable Replacement Cover g 22.5 22 Acceptable/Unacceptable Replacement

Gauge Gauge
unit in mm unit in mm

NI14002-010 NI14002-010

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-28 1002-28
Lower roller Lower roller

d d

f g f g
a

a
e

e
b

b
RI14001-004 RI14001-004

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
a Ø Ø130 Ø122 Acceptable/Unacceptable a Ø Ø130 Ø122 Acceptable/Unacceptable
Cladding by welding Cladding by welding
Track roller b 15 - Acceptable/Unacceptable Track roller b 15 - Acceptable/Unacceptable
or replacement or replacement
d 142 148 Acceptable/Unacceptable d 142 148 Acceptable/Unacceptable
Shaft e Ø Ø50 Ø49.5 Acceptable/Unacceptable Replacement Shaft e Ø Ø50 Ø49.5 Acceptable/Unacceptable Replacement
e Ø Ø50 Ø50.8 Acceptable/Unacceptable e Ø Ø50 Ø50.8 Acceptable/Unacceptable
Bushing Replacement Bushing Replacement
f 53 52.6 Acceptable/Unacceptable f 53 52.6 Acceptable/Unacceptable
Collar g 24.3 23.8 Acceptable/Unacceptable Replacement Collar g 24.3 23.8 Acceptable/Unacceptable Replacement

Gauge Gauge
unit in mm unit in mm

NI14002-011 NI14002-011

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-29 1002-29
Track Track

c
d

d
e' e e' e

f' f f' f

g' g g' g

h h h h
b

b
a

a
RI14001-005 RI14001-005

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Shoe plate a 28 18 Acceptable/Unacceptable Replacement Shoe plate a 28 18 Acceptable/Unacceptable Replacement
b 89 84 Acceptable/Unacceptable b 89 84 Acceptable/Unacceptable
Cladding by welding Cladding by welding
Link c 17 15 Acceptable/Unacceptable Link c 17 15 Acceptable/Unacceptable
or replacement or replacement
d 10.7 9 Acceptable/Unacceptable d 10.7 9 Acceptable/Unacceptable
e Ø Ø50.6 Ø49.5 Acceptable/Unacceptable e Ø Ø50.6 Ø49.5 Acceptable/Unacceptable
Master bushing Replacement Master bushing Replacement
f Ø Ø34.1 Ø35.5 Acceptable/Unacceptable f Ø Ø34.1 Ø35.5 Acceptable/Unacceptable
Master pin g Ø Ø33.25 Ø32.5 Acceptable/Unacceptable Replacement Master pin g Ø Ø33.25 Ø32.5 Acceptable/Unacceptable Replacement
Link pitch h 171.45 175 Acceptable/Unacceptable Replacement Link pitch h 171.45 175 Acceptable/Unacceptable Replacement
e' Ø Ø50.6 Ø49.5 Acceptable/Unacceptable e' Ø Ø50.6 Ø49.5 Acceptable/Unacceptable
Track bushing Replacement Track bushing Replacement
f' Ø Ø34.1 Ø35.5 Acceptable/Unacceptable f' Ø Ø34.1 Ø35.5 Acceptable/Unacceptable
Track pin g' Ø Ø33.5 Ø32.5 Acceptable/Unacceptable Replacement Track pin g' Ø Ø33.5 Ø32.5 Acceptable/Unacceptable Replacement

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-30 1002-30
DIMENSIONS AND WEAR LIMITS OF ATTACHMENT MOBILE JOINTS DIMENSIONS AND WEAR LIMITS OF ATTACHMENT MOBILE JOINTS
1 3 4 1 3 4

5 5
6 6

2 2
7 7

9 11 9 11
10 8 NI14002-012 10 8 NI14002-012

1. Boom foot/Frame 1. Boom foot/Frame

c c
d

d
e

e
a a
b b
NI14002-013 NI14002-013

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Swing frame a 569.5 577.5 Acceptable/Unacceptable - Swing frame a 569.5 577.5 Acceptable/Unacceptable -
Boom b 566 564 Acceptable/Unacceptable Replacement Boom b 566 564 Acceptable/Unacceptable Replacement
Clearance c 0.5 - 3.0 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 0.5 - 3.0 Adjust with shims Acceptable/Unacceptable Adjust with shims
Pin d Ø Ø75 Ø74 Acceptable/Unacceptable Replacement Pin d Ø Ø75 Ø74 Acceptable/Unacceptable Replacement
Bushing (boom) e Ø Ø75 Ø76.5 Acceptable/Unacceptable Replacement Bushing (boom) e Ø Ø75 Ø76.5 Acceptable/Unacceptable Replacement

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-31 1002-31
2. Boom cylinder foot/Frame 2. Boom cylinder foot/Frame
b c b c
a a

e
NI14002-014 NI14002-014

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Swing frame a 83.5 89.5 Acceptable/Unacceptable - Swing frame a 83.5 89.5 Acceptable/Unacceptable -
Boom cylinder b 82.5 80.5 Acceptable/Unacceptable Replacement Boom cylinder b 82.5 80.5 Acceptable/Unacceptable Replacement
(foot section) (foot section)
Clearance c 1.0 - 2.5 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 1.0 - 2.5 Adjust with shims Acceptable/Unacceptable Adjust with shims
Pin d Ø Ø70 Ø69 Acceptable/Unacceptable Replacement Pin d Ø Ø70 Ø69 Acceptable/Unacceptable Replacement
Bushing e Ø Ø70 Ø71.5 Acceptable/Unacceptable Replacement Bushing e Ø Ø70 Ø71.5 Acceptable/Unacceptable Replacement
(boom cylinder) (boom cylinder)

3. Boom cylinder head/Boom 3. Boom cylinder head/Boom


a b a a b a
c c
d
e

d
e
NI14002-015 NI14002-015

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Boom cylinder a 92 90 Acceptable/Unacceptable - Boom cylinder a 92 90 Acceptable/Unacceptable -
(top section) (top section)
Boom b 437 433 Acceptable/Unacceptable Replacement Boom b 437 433 Acceptable/Unacceptable Replacement
Clearance c 1.0 - 2.5 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 1.0 - 2.5 Adjust with shims Acceptable/Unacceptable Adjust with shims
Pin d Ø Ø70 Ø69 Acceptable/Unacceptable Replacement Pin d Ø Ø70 Ø69 Acceptable/Unacceptable Replacement
Bushing e Ø Ø70 Ø71.5 Acceptable/Unacceptable Replacement Bushing e Ø Ø70 Ø71.5 Acceptable/Unacceptable Replacement
(boom cylinder) (boom cylinder)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-32 1002-32
4. Dipper cylinder foot/Boom 4. Dipper cylinder foot/Boom
a a
b c b c

e
d

e
d
NI14002-016 NI14002-016

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Boom a 99 105 Acceptable/Unacceptable - Boom a 99 105 Acceptable/Unacceptable -
Boom cylinder b 98 96 Acceptable/Unacceptable Replacement Boom cylinder b 98 96 Acceptable/Unacceptable Replacement
(foot section) (foot section)
Clearance c 0.5 - 2.0 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 0.5 - 2.0 Adjust with shims Acceptable/Unacceptable Adjust with shims
Pin d Ø Ø70 Ø69 Acceptable/Unacceptable Replacement Pin d Ø Ø70 Ø69 Acceptable/Unacceptable Replacement
Bushing e Ø Ø70 Ø71.5 Acceptable/Unacceptable Replacement Bushing e Ø Ø70 Ø71.5 Acceptable/Unacceptable Replacement
(arm cylinder) (arm cylinder)

5. Boom/Dipper 5. Boom/Dipper
g b g g b g
a c a c
e

e
d

d
f

f
NI14002-017 NI14002-017

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Boom a 259 262 Acceptable/Unacceptable - Boom a 259 262 Acceptable/Unacceptable -
Arm b 256.5 254.5 Acceptable/Unacceptable Replacement Arm b 256.5 254.5 Acceptable/Unacceptable Replacement
Clearance c 0.5 - 1.1 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 0.5 - 1.1 Adjust with shims Acceptable/Unacceptable Adjust with shims
Pin d Ø Ø75 Ø74 Acceptable/Unacceptable Replacement Pin d Ø Ø75 Ø74 Acceptable/Unacceptable Replacement
Bushing (arm) e Ø Ø75 Ø76.5 Acceptable/Unacceptable Replacement Bushing (arm) e Ø Ø75 Ø76.5 Acceptable/Unacceptable Replacement
Boom f Ø Ø75 Ø76.5 Acceptable/Unacceptable Replacement Boom f Ø Ø75 Ø76.5 Acceptable/Unacceptable Replacement
Boom g 60 58 Acceptable/Unacceptable Replacement Boom g 60 58 Acceptable/Unacceptable Replacement

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-33 1002-33
6. Dipper cylinder head/Dipper 6. Dipper cylinder head/Dipper
b b
a a

d
e

e
c c
NI14002-018 NI14002-018

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Arm a 96.5 102.5 Acceptable/Unacceptable - Arm a 96.5 102.5 Acceptable/Unacceptable -
Arm cylinder b 95.5 93.5 Acceptable/Unacceptable Replacement Arm cylinder b 95.5 93.5 Acceptable/Unacceptable Replacement
(top section) (top section)
Clearance c 0.5 - 3.0 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 0.5 - 3.0 Adjust with shims Acceptable/Unacceptable Adjust with shims
Pin d Ø Ø70 Ø69 Acceptable/Unacceptable Replacement Pin d Ø Ø70 Ø69 Acceptable/Unacceptable Replacement
Bushing e Ø Ø70 Ø71.5 Acceptable/Unacceptable Replacement Bushing e Ø Ø70 Ø71.5 Acceptable/Unacceptable Replacement
(arm cylinder) (arm cylinder)

7. Bucket cylinder foot/Dipper 7. Bucket cylinder foot/Dipper


c d c

d
e

e
NI14002-019 NI14002-019

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Arm a 88 94 Acceptable/Unacceptable - Arm a 88 94 Acceptable/Unacceptable -
Bucket cylinder b 87 85 Acceptable/Unacceptable Replacement Bucket cylinder b 87 85 Acceptable/Unacceptable Replacement
(foot section) (foot section)
Clearance c 0.5 - 3.0 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 0.5 - 3.0 Adjust with shims Acceptable/Unacceptable Adjust with shims
Pin d Ø Ø65 Ø64 Acceptable/Unacceptable Replacement Pin d Ø Ø65 Ø64 Acceptable/Unacceptable Replacement
Bushing e Ø Ø65 Ø66.5 Acceptable/Unacceptable Replacement Bushing e Ø Ø65 Ø66.5 Acceptable/Unacceptable Replacement
(bucket cylinder) (bucket cylinder)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-34 1002-34
8. Connecting rod/Dipper 8. Connecting rod/Dipper
c c

a
b

b
a

a
e e
d d
NI14002-020 NI14002-020

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Arm link a 32 30 Acceptable/Unacceptable - Arm link a 32 30 Acceptable/Unacceptable -
Arm b 254 252 Acceptable/Unacceptable Replacement Arm b 254 252 Acceptable/Unacceptable Replacement
Clearance c 1.0 - 1.5 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 1.0 - 1.5 Adjust with shims Acceptable/Unacceptable Adjust with shims
Pin d Ø Ø65 Ø64 Acceptable/Unacceptable Replacement Pin d Ø Ø65 Ø64 Acceptable/Unacceptable Replacement
Bushing (arm) e Ø Ø65 Ø66.5 Acceptable/Unacceptable Replacement Bushing (arm) e Ø Ø65 Ø66.5 Acceptable/Unacceptable Replacement

9. Compensator/Bucket 9. Compensator/Bucket
d d
c c
e e
b
a

b
a
NI14002-021 NI14002-021

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Bucket a 255 251 Acceptable/Unacceptable - Bucket a 255 251 Acceptable/Unacceptable -
Bucket link b 254 252 Acceptable/Unacceptable Replacement Bucket link b 254 252 Acceptable/Unacceptable Replacement
Clearance c 1.0 - 3.5 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 1.0 - 3.5 Adjust with shims Acceptable/Unacceptable Adjust with shims
Pin d Ø Ø65 Ø64 Acceptable/Unacceptable Replacement Pin d Ø Ø65 Ø64 Acceptable/Unacceptable Replacement
Bushing e Ø Ø65 Ø66.5 Acceptable/Unacceptable Replacement Bushing e Ø Ø65 Ø66.5 Acceptable/Unacceptable Replacement
(bucket link) (bucket link)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-35 1002-35
10. Connecting rod/Compensator/Bucket cylinder head 10. Connecting rod/Compensator/Bucket cylinder head
c c
f f

a
i i

b
e
d

e
d
a

a
h h
g g
NI14002-022 NI14002-022

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Arm link a 32 30 Acceptable/Unacceptable - Arm link a 32 30 Acceptable/Unacceptable -
Bucket link b 254 252 Acceptable/Unacceptable Replacement Bucket link b 254 252 Acceptable/Unacceptable Replacement
Clearance c 1.0 - 1.5 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 1.0 - 1.5 Adjust with shims Acceptable/Unacceptable Adjust with shims
Bucket link d 92 94 Acceptable/Unacceptable Replacement Bucket link d 92 94 Acceptable/Unacceptable Replacement
Bucket cylinder e 91 89 Acceptable/Unacceptable Replacement Bucket cylinder e 91 89 Acceptable/Unacceptable Replacement
(top section) (top section)
Clearance f -0.5 - 2.0 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance f -0.5 - 2.0 Adjust with shims Acceptable/Unacceptable Adjust with shims
Pin g Ø Ø70 Ø69 Acceptable/Unacceptable Replacement Pin g Ø Ø70 Ø69 Acceptable/Unacceptable Replacement
Bushing h Ø Ø70 Ø71.5 Acceptable/Unacceptable Replacement Bushing h Ø Ø70 Ø71.5 Acceptable/Unacceptable Replacement
(bucket link) (bucket link)
Bushing i Ø Ø70 Ø71.5 Acceptable/Unacceptable Replacement Bushing i Ø Ø70 Ø71.5 Acceptable/Unacceptable Replacement
(bucket cylinder) (bucket cylinder)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-36 1002-36
11. Dipper/Bucket 11. Dipper/Bucket
e e
c g c g

d
f f

a
b

b
NI14002-023 NI14002-023

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Bucket a 255 261 Acceptable/Unacceptable - Bucket a 255 261 Acceptable/Unacceptable -
Arm b 254 252 Acceptable/Unacceptable Replacement Arm b 254 252 Acceptable/Unacceptable Replacement
Clearance c 1.0 - 3.5 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 1.0 - 3.5 Adjust with shims Acceptable/Unacceptable Adjust with shims
Bushing (bucket) d 16 8 Acceptable/Unacceptable Replacement Bushing (bucket) d 16 8 Acceptable/Unacceptable Replacement
Pin e Ø Ø65 Ø64 Acceptable/Unacceptable Replacement Pin e Ø Ø65 Ø64 Acceptable/Unacceptable Replacement
Bushing (arm) f Ø Ø65 Ø66.5 Acceptable/Unacceptable Replacement Bushing (arm) f Ø Ø65 Ø66.5 Acceptable/Unacceptable Replacement
Bushing (bucket) g Ø Ø65 Ø66.5 Acceptable/Unacceptable Replacement Bushing (bucket) g Ø Ø65 Ø66.5 Acceptable/Unacceptable Replacement

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-37 1002-37
DIMENSIONS AND WEAR LIMITS OF BLADE MOBILE JOINTS DIMENSIONS AND WEAR LIMITS OF BLADE MOBILE JOINTS

3 3

2 2

1 NI14002-024 1 NI14002-024

1. Blade/Blade cylinder head 1. Blade/Blade cylinder head


b b
a a
c c
d
e

d
e
NI14002-025 NI14002-025

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Blade a 71 77 Acceptable/Unacceptable Replacement Blade a 71 77 Acceptable/Unacceptable Replacement
Blade cylinder b 70 68 Acceptable/Unacceptable Replacement Blade cylinder b 70 68 Acceptable/Unacceptable Replacement
Clearance c 0.5 - 3.0 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 0.5 - 3.0 Adjust with shims Acceptable/Unacceptable Adjust with shims
(a - b) (a - b)
Pin d Ø Ø50 49 Acceptable/Unacceptable Replacement Pin d Ø Ø50 49 Acceptable/Unacceptable Replacement
Bushing e Ø Ø50 51.5 Acceptable/Unacceptable Replacement Bushing e Ø Ø50 51.5 Acceptable/Unacceptable Replacement
(blade cylinder) (blade cylinder)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-38 1002-38
2. Blade cylinder foot/Frame 2. Blade cylinder foot/Frame
b b
a a
c c

d
e

d
e
NI14002-026 NI14002-026

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Lower frame a 74 80 Acceptable/Unacceptable Replacement Lower frame a 74 80 Acceptable/Unacceptable Replacement
Blade cylinder b 70 68 Acceptable/Unacceptable Replacement Blade cylinder b 70 68 Acceptable/Unacceptable Replacement
Clearance c 4.0 - 5.5 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 4.0 - 5.5 Adjust with shims Acceptable/Unacceptable Adjust with shims
(a - b) (a - b)
Pin d Ø Ø50 Ø49 Acceptable/Unacceptable Replacement Pin d Ø Ø50 Ø49 Acceptable/Unacceptable Replacement
Bushing e Ø Ø50 Ø51.5 Acceptable/Unacceptable Replacement Bushing e Ø Ø50 Ø51.5 Acceptable/Unacceptable Replacement
(blade cylinder) (blade cylinder)

3. Blade/Frame 3. Blade/Frame
d
e

d
e
c c
a a
b b
NI14002-027 NI14002-027

Measured Measured
Standard Usage limit Standard Usage limit
Part name Code dimensions Judgment Solution Part name Code dimensions Judgment Solution
value (mm) (mm) value (mm) (mm)
(mm) (mm)
Lower frame a 74 80 Acceptable/Unacceptable Replacement Lower frame a 74 80 Acceptable/Unacceptable Replacement
Blade b 70 68 Acceptable/Unacceptable Replacement Blade b 70 68 Acceptable/Unacceptable Replacement
Clearance c 4.0 - 5.5 Adjust with shims Acceptable/Unacceptable Adjust with shims Clearance c 4.0 - 5.5 Adjust with shims Acceptable/Unacceptable Adjust with shims
(a - b) (a - b)
Pin d Ø Ø60 Ø59 Acceptable/Unacceptable Replacement Pin d Ø Ø60 Ø59 Acceptable/Unacceptable Replacement
Bushing e Ø Ø60 Ø61.5 Acceptable/Unacceptable Replacement Bushing e Ø Ø60 Ø61.5 Acceptable/Unacceptable Replacement
(blade) (blade)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-39 1002-39
SPECIAL TORQUE SETTINGS SPECIAL TORQUE SETTINGS
No. Component Screw Wrench (mm) Torque setting No. Component Screw Wrench (mm) Torque setting
1* Travel motor and reduction gear assembly M16 24 267-312 Nm (197-230 lb-ft) 1* Travel motor and reduction gear assembly M16 24 267-312 Nm (197-230 lb-ft)
2* Drive sprocket M16 24 267-312 Nm (197-230 lb-ft) 2* Drive sprocket M16 24 267-312 Nm (197-230 lb-ft)
3* Idler wheel M16 24 267-312 Nm (197-230 lb-ft) 3* Idler wheel M16 24 267-312 Nm (197-230 lb-ft)
4* Upper roller M16 24 267-312 Nm (197-230 lb-ft) 4* Upper roller M16 24 267-312 Nm (197-230 lb-ft)
5* Lower roller M16 24 267-312 Nm (197-230 lb-ft) 5* Lower roller M16 24 267-312 Nm (197-230 lb-ft)
6 Shoe bolt M16 30 373-451 Nm (275-330 ibf-ft) 6 Shoe bolt M16 30 373-451 Nm (275-330 ibf-ft)
7 Counterweight M27 50 1078-1274 Nm (795-940 lb-ft) 7 Counterweight M27 50 1078-1274 Nm (795-940 lb-ft)
8* Turntable bearing (lower frame) M16 24 280-312 Nm (206-230 lb-ft) 8* Turntable bearing (lower frame) M16 24 280-312 Nm (206-230 lb-ft)
9* Turntable (swing frame) M16 24 280-312 Nm (206-230 lb-ft) 9* Turntable (swing frame) M16 24 280-312 Nm (206-230 lb-ft)
10 * Swing unit M16 24 280-312 Nm (206-230 lb-ft) 10 * Swing unit M16 24 280-312 Nm (206-230 lb-ft)
11 * Engine (engine mount) M16 24 265-314 Nm (196-231 lb-ft) 11 * Engine (engine mount) M16 24 265-314 Nm (196-231 lb-ft)
12 * Engine bracket M12 19 64-74 Nm (47.20-54.58 lb-ft) 12 * Engine bracket M12 19 64-74 Nm (47.20-54.58 lb-ft)
13 Radiator M12 19 64-74 Nm (47.20-54.58 lb-ft) 13 Radiator M12 19 64-74 Nm (47.20-54.58 lb-ft)
14 * M10 17 64-73 Nm (47-54 lb-ft) 14 * M10 17 64-73 Nm (47-54 lb-ft)
Hydraulic pump 14 Hydraulic pump 14
15 * M16 223-247 Nm (165-182 lb-ft) 15 * M16 223-247 Nm (165-182 lb-ft)
bar wrench bar wrench
16 * Hydraulic reservoir M16 24 232-276 Nm (172-203 lb-ft) 16 * Hydraulic reservoir M16 24 232-276 Nm (172-203 lb-ft)
17 * Fuel reservoir M16 24 232-276 Nm (172-203 lb-ft) 17 * Fuel reservoir M16 24 232-276 Nm (172-203 lb-ft)
18 * Control valve M16 24 267-312 Nm (197-230 lb-ft) 18 * Control valve M16 24 267-312 Nm (197-230 lb-ft)
19 * M12 19 88-107 Nm (65-78 lb-ft) 19 * M12 19 88-107 Nm (65-78 lb-ft)
Hydraulic swivel Hydraulic swivel
20 M16 24 109-127 Nm (81-93 lb-ft) 20 M16 24 109-127 Nm (81-93 lb-ft)
21 Cab M16 24 157 Nm (116 lb-ft) 21 Cab M16 24 157 Nm (116 lb-ft)
22 Battery M10 17 20-29 Nm (14.75-21.39 lb-ft) 22 Battery M10 17 20-29 Nm (14.75-21.39 lb-ft)

NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*). NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-40 1002-40

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-41 1002-41

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-42 1002-42

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-43 1002-43
MACHINE OVERALL DIMENSIONS MACHINE OVERALL DIMENSIONS
NOTE: Numbers are subject to change without notice due to design change or other reasons. NOTE: Numbers are subject to change without notice due to design change or other reasons.
The figures give values that include the shoe lug height (20 mm (0.79 in) The figures give values that include the shoe lug height (20 mm (0.79 in)

Standard Arm (Dipper) (2500 mm (98.42 in)) Standard Arm (Dipper) (2500 mm (98.42 in))
CX130B CX130B

Standard Arm (Dipper) (2500 mm (98.42 in)) Standard Arm (Dipper) (2500 mm (98.42 in))
CX130B (LC) CX130B (LC)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-44 1002-44
Standard Arm (Dipper) (2500 mm (98.42 in)) Standard Arm (Dipper) (2500 mm (98.42 in))
CX130B (Blade) CX130B (Blade)

Standard Arm (Dipper) (2500 mm (98.42 in)) Standard Arm (Dipper) (2500 mm (98.42 in))
CX130B 2PC CX130B 2PC

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-45 1002-45
Standard Arm (Dipper) (2500 mm (98.42 in)) Standard Arm (Dipper) (2500 mm (98.42 in))
CX130B 2PC (Blade) CX130B 2PC (Blade)

Short Arm (Dipper) (2110 mm (82.68 in)) Short Arm (Dipper) (2110 mm (82.68 in))
CX130B CX130B

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-46 1002-46
Short Arm (Dipper) (2110 mm (83.07 in)) Short Arm (Dipper) (2110 mm (83.07 in))
CX130B (LC) CX130B (LC)

Short Arm (Dipper) (2110 mm (83.07 in)) Short Arm (Dipper) (2110 mm (83.07 in))
CX130B (Blade) CX130B (Blade)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-47 1002-47
Short Arm (Dipper) (2110 mm (82.68 in)) Short Arm (Dipper) (2110 mm (82.68 in))
CX130B 2PC CX130B 2PC

Short Arm (Dipper) (2110 mm (82.68 in)) Short Arm (Dipper) (2110 mm (82.68 in))
CX130B 2PC (Blade) CX130B 2PC (Blade)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-48 1002-48
Long Arm (Dipper) (3010 mm (118.50 in)) Long Arm (Dipper) (3010 mm (118.50 in))
CX130B CX130B

Long Arm (Dipper) (3010 mm (118.50 in)) Long Arm (Dipper) (3010 mm (118.50 in))
CX130B (LC) CX130B (LC)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-49 1002-49
Long Arm (Dipper) (3010 mm (118.50 in)) Long Arm (Dipper) (3010 mm (118.50 in))
CX130B (Blade) CX130B (Blade)

Long Arm (Dipper) (3010 mm (118.50 in)) Long Arm (Dipper) (3010 mm (118.50 in))
CX130B 2PC CX130B 2PC

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


1002-50 1002-50
Long Arm (Dipper) (3010 mm (118.50 in)) Long Arm (Dipper) (3010 mm (118.50 in))
CX130B 2PC (Blade) CX130B 2PC (Blade)

Lep SC130B1002-2EN Issued 03-08 Lep SC130B1002-2EN Issued 03-08


Section Section
2000 2000

REMOVAL AND INSTALLATION OF THE ENGINE REMOVAL AND INSTALLATION OF THE ENGINE

2000

2000
Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B2000-0EN March 2008 CNH Lep SM130B2000-0EN March 2008
2000-2 2000-2
TABLE OF CONTENTS TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF THE ENGINE ASSEMBLY ......................................................................... 3 REMOVAL AND INSTALLATION OF THE ENGINE ASSEMBLY ......................................................................... 3
REMOVAL OF THE ENGINE ...................................................................................................................................... 3 REMOVAL OF THE ENGINE ...................................................................................................................................... 3
INSTALLATION OF THE ENGINE ............................................................................................................................. 12 INSTALLATION OF THE ENGINE ............................................................................................................................. 12

Lep SM130B2000-0EN Issued 03-08 Lep SM130B2000-0EN Issued 03-08


2000-3 2000-3
REMOVAL AND INSTALLATION OF THE ENGINE ASSEMBLY REMOVAL AND INSTALLATION OF THE ENGINE ASSEMBLY

Keep away from fire. Keep away from fire.


Be sure to release hydraulic pressure before beginning work. Be sure to release hydraulic pressure before beginning work.
Caution: The air conditioner circuit is filled with high-pressure gas, so there is the danger of Caution: The air conditioner circuit is filled with high-pressure gas, so there is the danger of
gas splaying out when loosening lines. gas splaying out when loosening lines.
Do not use open flames and do not allow sparks near the battery. Do not use open flames and do not allow sparks near the battery.

Be sure to stop the engine before beginning work. Be sure to stop the engine before beginning work.
Caution: Be sure to inspect the wire rope and other lifting equipment before beginning work. Caution: Be sure to inspect the wire rope and other lifting equipment before beginning work.
Do not stand or pass under the suspended load. Do not stand or pass under the suspended load.
1 Removal of the engine 1 Removal of the engine
[1] Remove the counterweight. [1] Remove the counterweight.
(For details, see "Removal and Installation of Coun- (For details, see "Removal and Installation of Coun-
terweight") terweight")
[2] Remove the pump. [2] Remove the pump.
(For details, see "Removal and Installation of (For details, see "Removal and Installation of
Pump") Pump")
[3] Disassemble the retaining screws (1) and (2), and [3] Disassemble the retaining screws (1) and (2), and
then remove the fan shroud (3). then remove the fan shroud (3).

Lep SM130B2000-0EN Issued 03-08 Lep SM130B2000-0EN Issued 03-08


2000-4 2000-4

[4] Disassemble the retaining screws (1), and then [4] Disassemble the retaining screws (1), and then
remove the fan guard (2). 2 remove the fan guard (2). 2
1 1

1 1

RF11001-007 RF11001-007

[5] Loosen the hoseband (1), and then remove the [5] Loosen the hoseband (1), and then remove the
upper hose (2) from the radiator. upper hose (2) from the radiator.

1 1

2 2

[6] Loosen the hoseband (3), and then remove the [6] Loosen the hoseband (3), and then remove the
lower hose (4) from the radiator. lower hose (4) from the radiator.
• Use caps to cover the radiator and hoses and pre- • Use caps to cover the radiator and hoses and pre-
vent the entry of water, dust or dirt. vent the entry of water, dust or dirt.
• Before removing the radiator hoses, completely • Before removing the radiator hoses, completely
drain the coolant. 3 drain the coolant. 3

4 4

[7] Loosen the adjusting bolts (1) on the pipe, and then [7] Loosen the adjusting bolts (1) on the pipe, and then
remove the 2 pipes (2) and (3) from the compressor. remove the 2 pipes (2) and (3) from the compressor.
• Always remove the low-pressure pipe (2) first. • Always remove the low-pressure pipe (2) first.
• Attach caps or plugs to the compressor and pipes to • Attach caps or plugs to the compressor and pipes to
prevent any entry of water, dust or dirt. prevent any entry of water, dust or dirt.

2 1 3 2 1 3
NF11002-008 NF11002-008

Lep SM130B2000-0EN Issued 03-08 Lep SM130B2000-0EN Issued 03-08


2000-5 2000-5
[8] Loosen the hoseband (1) on the inter cooler, and [8] Loosen the hoseband (1) on the inter cooler, and
then remove the hose (2). then remove the hose (2).
• Use caps to cover the pipe and hose and prevent • Use caps to cover the pipe and hose and prevent
the entry of water, dust or dirt the entry of water, dust or dirt

2 2

1 1

NF11002-009 NF11002-009

[9] Remove the hosebands (1) in the three locations. [9] Remove the hosebands (1) in the three locations.

1 1

NF11002-010 NF11002-010

[10]Insert inside the breather hose (1) that is on the [10]Insert inside the breather hose (1) that is on the
outside. outside.

1 1

NF11002-011 NF11002-011

Lep SM130B2000-0EN Issued 03-08 Lep SM130B2000-0EN Issued 03-08


2000-6 2000-6
[11]Prepare a waste oil can (1). As the engine oil hose [11]Prepare a waste oil can (1). As the engine oil hose
will be removed, first drain the engine oil. will be removed, first drain the engine oil.

1 1

NF11002-012 NF11002-012

[12]Remove the hoses (1). [12]Remove the hoses (1).


• Mark the engine and hoses so that the connectors • Mark the engine and hoses so that the connectors
match at the time of assembly. match at the time of assembly.
• Attach caps or plugs to the engine and hoses to pre- • Attach caps or plugs to the engine and hoses to pre-
vent any entry of water, dust or dirt. vent any entry of water, dust or dirt.
• Clean the engine and hoses by spraying with a parts • Clean the engine and hoses by spraying with a parts
cleaner to prevent scratches and prevent dirt from cleaner to prevent scratches and prevent dirt from
accumulating on the connectors. accumulating on the connectors.

1 NF11002-013
1 NF11002-013

[13]Remove the bolt (1), and then remove the battery [13]Remove the bolt (1), and then remove the battery
cable (2) on the negative side. cable (2) on the negative side.
2 2
• When removing the terminal and harness, secure • When removing the terminal and harness, secure
them so that do not interfere with the frame. them so that do not interfere with the frame.
Also, cover with a rubber cap to protect against Also, cover with a rubber cap to protect against
sparks. sparks.

1 1

NF11002-014 NF11002-014

Lep SM130B2000-0EN Issued 03-08 Lep SM130B2000-0EN Issued 03-08


2000-7 2000-7
[14]Remove the nut (1), and then remove the wire (2) [14]Remove the nut (1), and then remove the wire (2)
from the starter motor. from the starter motor.

1 1

2 NF11002-015
2 NF11002-015

[15]Remove the jump-start protector (3), remove the [15]Remove the jump-start protector (3), remove the
nut (1), and then remove the wire (2) from the nut (1), and then remove the wire (2) from the
starter motor. starter motor.
1 1

3 3

2 2

NF11002-016 NF11002-016

[16]Remove the hose stopper (1), and then remove the [16]Remove the hose stopper (1), and then remove the
fuel hose (2). fuel hose (2).
• Attach caps or plugs to the engine and hoses to pre- • Attach caps or plugs to the engine and hoses to pre-
vent any entry of water, dust or dirt. vent any entry of water, dust or dirt.

1 1
2 2

NF11002-017 NF11002-017

[17]Remove the hose stopper (1), and then remove the [17]Remove the hose stopper (1), and then remove the
fuel hose (2). fuel hose (2).
• Attach caps or plugs to the engine and hoses to pre- • Attach caps or plugs to the engine and hoses to pre-
vent any entry of water, dust or dirt. vent any entry of water, dust or dirt.

2 2
1 1

NF11002-018 NF11002-018

Lep SM130B2000-0EN Issued 03-08 Lep SM130B2000-0EN Issued 03-08


2000-8 2000-8
[18]Disassemble the retaining screws (1), and then [18]Disassemble the retaining screws (1), and then
remove the box cover (2). remove the box cover (2).

1 1

2 2

NF11002-019 NF11002-019

[19]Remove the connectors (1) in the box. [19]Remove the connectors (1) in the box.
• After tying the connectors together, put them in a • After tying the connectors together, put them in a
plastic bag. plastic bag.

1 1

NF11002-020 NF11002-020

[20]Loosen the hoseband (1), and then remove the [20]Loosen the hoseband (1), and then remove the
heater hose (2). heater hose (2).
• Attach caps or plugs to the engine and hoses to pre- • Attach caps or plugs to the engine and hoses to pre-
vent any entry of water, dust or dirt. vent any entry of water, dust or dirt.

1 1
2 2

NF11002-021 NF11002-021

[21]Loosen the hoseband (1), and then remove the [21]Loosen the hoseband (1), and then remove the
heater hose (2). heater hose (2).
• Attach caps or plugs to the engine and hoses to pre- • Attach caps or plugs to the engine and hoses to pre-
vent any entry of water, dust or dirt. vent any entry of water, dust or dirt.
1 1
2 2

NF11002-022 NF11002-022

Lep SM130B2000-0EN Issued 03-08 Lep SM130B2000-0EN Issued 03-08


2000-9 2000-9
[22]Loosen the hoseband (1), and then remove the [22]Loosen the hoseband (1), and then remove the
radiator hose (2). radiator hose (2).
• Use caps to cover the line and hose and prevent the • Use caps to cover the line and hose and prevent the
entry of water, dust or dirt. entry of water, dust or dirt.

2 2

1 1

NF11002-023 NF11002-023

[23]Loosen the hoseband (1), and then remove the air [23]Loosen the hoseband (1), and then remove the air
hose (2). hose (2).
• Use caps to cover the line and hose and prevent the • Use caps to cover the line and hose and prevent the
entry of water, dust or dirt. entry of water, dust or dirt.

2 2

1 1

NF11002-024 NF11002-024

[24]Loosen the hoseband (1), and then remove the air [24]Loosen the hoseband (1), and then remove the air
hose (2). hose (2).
• Use caps to cover the line and hose and prevent the • Use caps to cover the line and hose and prevent the
entry of water, dust or dirt. entry of water, dust or dirt.

2 2

1 1

NF11002-025 NF11002-025

[25]Remove the connector (1) from the alternator. [25]Remove the connector (1) from the alternator.

1 1

NF11002-026 NF11002-026

Lep SM130B2000-0EN Issued 03-08 Lep SM130B2000-0EN Issued 03-08


2000-10 2000-10
[26]Remove the nut (1), and then remove the wires (2) [26]Remove the nut (1), and then remove the wires (2)
from the alternator. from the alternator.
2 2

1 1

NF11002-027 NF11002-027

[27]Remove the bolt (1), and then remove the breather [27]Remove the bolt (1), and then remove the breather
hose clamp (2). hose clamp (2).

2 2
1 1

NF11002-029 NF11002-029

[28]Connect the 2 shackles (1), and then use the wires [28]Connect the 2 shackles (1), and then use the wires
and crane to secure the engine. and crane to secure the engine.
1 1

1 1

NF11002-030 NF11002-030

Lep SM130B2000-0EN Issued 03-08 Lep SM130B2000-0EN Issued 03-08


2000-11 2000-11
[29]Disassemble the retaining screws (1) from the [29]Disassemble the retaining screws (1) from the
mount. 1 mount. 1
1 1

1 1

1 1

NF11002-031 NF11002-031

[30]Use the wires and crane to lift the engine. [30]Use the wires and crane to lift the engine.
[31]Thoroughly check that the location is safe before [31]Thoroughly check that the location is safe before
lowering the engine on wood planks, etc. lowering the engine on wood planks, etc.

NF11002-032 NF11002-032

Lep SM130B2000-0EN Issued 03-08 Lep SM130B2000-0EN Issued 03-08


2000-12 2000-12
2 Installation of the engine 2 Installation of the engine
[1] To install the engine, perform the reverse of the removal procedure. [1] To install the engine, perform the reverse of the removal procedure.
After installing the engine, resupply coolant and engine oil, perform fuel line air bleeding, and perform filling for the After installing the engine, resupply coolant and engine oil, perform fuel line air bleeding, and perform filling for the
air conditioner gas. air conditioner gas.
For details, see the individual explanations for each procedure. For details, see the individual explanations for each procedure.
[2] Run the engine at no-load idling and check for any water or oil leaks. [2] Run the engine at no-load idling and check for any water or oil leaks.
[3] Attach the hydraulic pump, covers, and counterweight. [3] Attach the hydraulic pump, covers, and counterweight.
For details, see the individual explanations for each procedure. For details, see the individual explanations for each procedure.

Lep SM130B2000-0EN Issued 03-08 Lep SM130B2000-0EN Issued 03-08


2001

2001
Section Section
2001 2001

REMOVAL AND INSTALLATION OF THE FUEL- REMOVAL AND INSTALLATION OF THE FUEL-
COOLER, ENGINE INTER-COOLER, RADIATOR AND COOLER, ENGINE INTER-COOLER, RADIATOR AND
OIL-COOLER OIL-COOLER

Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B2001-0EN March 2008 CNH Lep SM130B2001-0EN March 2008
2001-2 2001-2

TABLE OF CONTENTS TABLE OF CONTENTS


REMOVAL AND INSTALLATION OF FUEL COOLER .......................................................................................... 3 REMOVAL AND INSTALLATION OF FUEL COOLER .......................................................................................... 3
REMOVAL OF FUEL COOLER .................................................................................................................................. 3 REMOVAL OF FUEL COOLER .................................................................................................................................. 3
INSTALLATION THE FUEL COOLER .......................................................................................................................... 3 INSTALLATION THE FUEL COOLER .......................................................................................................................... 3
REMOVAL AND INSTALLATION OF INTER COOLER......................................................................................... 4 REMOVAL AND INSTALLATION OF INTER COOLER......................................................................................... 4
REMOVAL OF INTER COOLER ................................................................................................................................. 4 REMOVAL OF INTER COOLER ................................................................................................................................. 4
INSTALLATION OF INTER COOLER ........................................................................................................................... 5 INSTALLATION OF INTER COOLER ........................................................................................................................... 5
REMOVAL AND INSTALLATION OF RADIATOR ................................................................................................. 6 REMOVAL AND INSTALLATION OF RADIATOR ................................................................................................. 6
REMOVAL OF RADIATOR ........................................................................................................................................ 6 REMOVAL OF RADIATOR ........................................................................................................................................ 6
INSTALLATION OF RADIATOR................................................................................................................................ 12 INSTALLATION OF RADIATOR................................................................................................................................ 12
REMOVAL AND INSTALLATION OF OIL COOLER............................................................................................ 13 REMOVAL AND INSTALLATION OF OIL COOLER............................................................................................ 13
REMOVAL OF OIL COOLER ................................................................................................................................... 13 REMOVAL OF OIL COOLER ................................................................................................................................... 13
INSTALLATION OF OIL COOLER............................................................................................................................. 16 INSTALLATION OF OIL COOLER............................................................................................................................. 16

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-3 2001-3
REMOVAL AND INSTALLATION OF FUEL COOLER REMOVAL AND INSTALLATION OF FUEL COOLER
Be sure to stop the engine before beginning work. Be sure to stop the engine before beginning work.
Caution: Caution:
As the fuel hose will be removed, strictly prohibit open flames. As the fuel hose will be removed, strictly prohibit open flames.
1 Removal of fuel cooler 1 Removal of fuel cooler
[1] Mark the fuel cooler and hoses so that the connec- [1] Mark the fuel cooler and hoses so that the connec-
tors match at the time of assembly. 2 4 tors match at the time of assembly. 2 4
Loosen the hosebands (3) and (4), and then remove Loosen the hosebands (3) and (4), and then remove
the hoses (1) and (2). the hoses (1) and (2).
• Attach caps or plugs to the fuel cooler and hoses to • Attach caps or plugs to the fuel cooler and hoses to
prevent any entry of water, dust or dirt. prevent any entry of water, dust or dirt.

1 3 1 3

NF11002-060 NF11002-060

[2] Disassemble the retaining screws (1), and then [2] Disassemble the retaining screws (1), and then
remove the fuel cooler unit (2). remove the fuel cooler unit (2).

1 1

2 2
NF11002-061 NF11002-061

2 Installation the fuel cooler 2 Installation the fuel cooler


Perform the reverse of the removal procedure. Perform the reverse of the removal procedure.
• After connecting the hoses, carefully check for any fuel leaks. • After connecting the hoses, carefully check for any fuel leaks.

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-4 2001-4
REMOVAL AND INSTALLATION OF INTER COOLER REMOVAL AND INSTALLATION OF INTER COOLER
Be sure to stop the engine before beginning work. Be sure to stop the engine before beginning work.
Caution: Caution:
As the fuel hose will be removed, strictly prohibit open flames. As the fuel hose will be removed, strictly prohibit open flames.
1 Removal of inter cooler 1 Removal of inter cooler
[1] Remove the fuel cooler. [1] Remove the fuel cooler.
(For details, see "Removal and Installation of Fuel (For details, see "Removal and Installation of Fuel
Cooler") Cooler")
[2] Loosen the bolts (1), and then remove the cover (2). 2 [2] Loosen the bolts (1), and then remove the cover (2). 2

1 1

NF11002-066 NF11002-066

[3] Loosen the hosebands (1) in the two locations, and [3] Loosen the hosebands (1) in the two locations, and
then remove the hoses (2). then remove the hoses (2).

1 1

2 2

NF11002-067 NF11002-067

[4] Loosen the hosebands (1) in the two locations, and [4] Loosen the hosebands (1) in the two locations, and
then remove the hoses (2). then remove the hoses (2).

1 1

2 2
NF11002-068 NF11002-068

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-5 2001-5
[5] Remove the bolt (1). [5] Remove the bolt (1).
1 1

NF11002-069 NF11002-069

[6] Attach a wire to the top section of the inter cooler [6] Attach a wire to the top section of the inter cooler
using a shackle, and lift the inter cooler to remove it. using a shackle, and lift the inter cooler to remove it.

NF11002-070 NF11002-070

2 Installation of inter cooler 2 Installation of inter cooler


Perform the reverse of the removal procedure. Perform the reverse of the removal procedure.
Check for any air leaks. Check for any air leaks.

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-6 2001-6
REMOVAL AND INSTALLATION OF RADIATOR REMOVAL AND INSTALLATION OF RADIATOR
Do not remove the radiator cap when the radiator coolant temperature is high. Hot Do not remove the radiator cap when the radiator coolant temperature is high. Hot
Caution: Caution:
liquid could spray out. liquid could spray out.

Be sure to release hydraulic pressure before beginning work. Be sure to release hydraulic pressure before beginning work.
Be sure to stop the engine before beginning work. Be sure to stop the engine before beginning work.
Caution: Caution:
Be sure to inspect the wire rope and other lifting equipment before beginning work. Be sure to inspect the wire rope and other lifting equipment before beginning work.
Do not stand or pass under the suspended load. Do not stand or pass under the suspended load.
1 Removal of radiator 1 Removal of radiator
[1] Disassemble the retaining screws (1), and then [1] Disassemble the retaining screws (1), and then
remove the under cover (2). remove the under cover (2).

1 1

2 2

NM13002-001 NM13002-001

[2] Install the drain hose (1), and then prepare the drain [2] Install the drain hose (1), and then prepare the drain
tank (2). tank (2).

1 1

2 2

NM13002-002 NM13002-002

[3] To make it easier to drain the coolant, remove the [3] To make it easier to drain the coolant, remove the
radiator cap (1). radiator cap (1).

1 1
NM13002-003 NM13002-003

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-7 2001-7
[4] Loosen the drain plug (1), and then drain the cool- [4] Loosen the drain plug (1), and then drain the cool-
ant. ant.

1 1

NM13002-004 NM13002-004

[5] Loosen the hoseband (1), and then remove the [5] Loosen the hoseband (1), and then remove the
hose (2). hose (2).
• Use caps to cover the pipe and hose and prevent • Use caps to cover the pipe and hose and prevent
the entry of water, dust or dirt. the entry of water, dust or dirt.
1 1

2 2

NM13002-005 NM13002-005

[6] Remove the bolts (1), and then remove the cover [6] Remove the bolts (1), and then remove the cover
(2). 1 (2). 1
2 2

NM13002-006 NM13002-006

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-8 2001-8
[7] Disassemble the retaining screws (1) from the radia- [7] Disassemble the retaining screws (1) from the radia-
tor cover. tor cover.

1 NM13002-007 1 NM13002-007

[8] Loosen the hoseband (1), and then remove the [8] Loosen the hoseband (1), and then remove the
upper hose (2) from the radiator. upper hose (2) from the radiator.
Loosen the hoseband (3), and then remove the Loosen the hoseband (3), and then remove the
lower hose (4) from the radiator. lower hose (4) from the radiator.
• Use caps to cover the radiator and hoses and pre- 1 • Use caps to cover the radiator and hoses and pre- 1
vent the entry of water, dust or dirt. vent the entry of water, dust or dirt.
2 2

3 3

4 4
NM13002-008 NM13002-008

[9] Remove the drain plug (1), Loosen the hoseband [9] Remove the drain plug (1), Loosen the hoseband
(2), and then remove the hose (3). (2), and then remove the hose (3).
1 1

2 2

3 3

NM13002-009 NM13002-009

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-9 2001-9
[10]Loosen the hoseband (1), and then remove the [10]Loosen the hoseband (1), and then remove the
hose (2) from the radiator cap. 1 2 hose (2) from the radiator cap. 1 2
• Attach caps or plugs to the hoses to prevent any • Attach caps or plugs to the hoses to prevent any
entry of water, dust or dirt. entry of water, dust or dirt.

NM13002-010 NM13002-010

[11]Turn up the rubber band on the fan. [11]Turn up the rubber band on the fan.

1 1

NM13002-011 NM13002-011

[12]Loosen the hosebands (1) and (2), and then [12]Loosen the hosebands (1) and (2), and then
remove the hoses (3) from the bracket (4). 3 remove the hoses (3) from the bracket (4). 3
1 1
• Use caps to cover the hoses and pipes and prevent • Use caps to cover the hoses and pipes and prevent
the entry of water, dust or dirt. the entry of water, dust or dirt.

4 3 4 3

2 2

NM13002-012 NM13002-012

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-10 2001-10
[13]Remove the connector (1) from the sensor. [13]Remove the connector (1) from the sensor.

1 1

NM13002-013 NM13002-013

[14]Disassemble the retaining screws (1), (2) and (3), [14]Disassemble the retaining screws (1), (2) and (3),
and then remove the fan shroud (4). 1 and then remove the fan shroud (4). 1

NM13002-017 NM13002-017

3 3

2 2

4 NM13002-018 4 NM13002-018

[15]Disassemble the retaining screws (1) and (2) from [15]Disassemble the retaining screws (1) and (2) from
the fan guard, and then move the fan guard towards 3 the fan guard, and then move the fan guard towards 3
the engine. the engine.
1 1

3 3

2 2
NM13002-019 NM13002-019

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-11 2001-11
[16]Remove the bolts (1), washers (2), and then [16]Remove the bolts (1), washers (2), and then
remove the radiator cover (3). remove the radiator cover (3).
3 3

2 2
1 1

NM13002-020 NM13002-020

[17]Remove the 2 butterfly bolts (1), and then remove [17]Remove the 2 butterfly bolts (1), and then remove
the front anti-insect net (2). 1 the front anti-insect net (2). 1

2 2

NM13002-021 NM13002-021

[18]Connect the 2 shackles to the top of the radiator, [18]Connect the 2 shackles to the top of the radiator,
and then use the wires and crane to lift the radiator. and then use the wires and crane to lift the radiator.

NM13002-022 NM13002-022

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-12 2001-12
[19]Lift the radiator together with the radiator cover (2) [19]Lift the radiator together with the radiator cover (2)
until the fixtures (1) at the bottom of the radiator until the fixtures (1) at the bottom of the radiator
become disconnected. become disconnected.

2 2
1 1

NM13002-025 NM13002-025

[20]Thoroughly check that the location is safe before [20]Thoroughly check that the location is safe before
lowering the radiator on a crosstie. lowering the radiator on a crosstie.
[21] [21]

2 Installation of radiator 2 Installation of radiator


Perform the reverse of the removal procedure. Perform the reverse of the removal procedure.
For details on the method for coolant filling, see the Operator’s Manual. For details on the method for coolant filling, see the Operator’s Manual.
Finally, check that the level of coolant is correct. Finally, check that the level of coolant is correct.

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-13 2001-13
REMOVAL AND INSTALLATION OF OIL COOLER REMOVAL AND INSTALLATION OF OIL COOLER
Caution: Keep away from fire Caution: Keep away from fire

Be sure to stop the engine before beginning work. Be sure to stop the engine before beginning work.
Caution: Be sure to inspect the wire rope and other lifting equipment before beginning work. Caution: Be sure to inspect the wire rope and other lifting equipment before beginning work.
Do not stand or pass under the suspended load. Do not stand or pass under the suspended load.
1 Removal of oil cooler 1 Removal of oil cooler
[1] Drain the hydraulic oil from the hydraulic oil tank. [1] Drain the hydraulic oil from the hydraulic oil tank.
See Operator’s Manual for details of this procedure. See Operator’s Manual for details of this procedure.
[2] Disassemble the retaining screws (1), and then [2] Disassemble the retaining screws (1), and then
remove the under cover (2). remove the under cover (2).

1 1

2 2

NF13002-023 NF13002-023

[3] Prepare a waste oil can (1). [3] Prepare a waste oil can (1).

1 1

NM13002-024 NM13002-024

[4] Use pliers to remove the 2 butterfly screws (1), and [4] Use pliers to remove the 2 butterfly screws (1), and
then remove the anti-insect net (2). 1 2 then remove the anti-insect net (2). 1 2

NM13002-027 NM13002-027

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-14 2001-14
[5] Remove the hose clamps (1), and then remove the [5] Remove the hose clamps (1), and then remove the
hose (2). hose (2).

1 2 NM13002-028 1 2 NM13002-028

[6] Remove the bolts (8), and then remove the line (2). [6] Remove the bolts (8), and then remove the line (2).
• Use caps to cover the oil cooler and lines and pre- • Use caps to cover the oil cooler and lines and pre-
vent the entry of water, dust or dirt. vent the entry of water, dust or dirt.

1 2 NM13002-029 1 2 NM13002-029

[7] Remove the 2 upper bolts (1) and 2 lower bolts (2) [7] Remove the 2 upper bolts (1) and 2 lower bolts (2)
securing the oil cooler. 1 securing the oil cooler. 1

2 2

NM13002-030 NM13002-030

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-15 2001-15
[8] Install 2 8-mm eyebolts (1) on the top of the oil [8] Install 2 8-mm eyebolts (1) on the top of the oil
cooler. cooler.
1 1
• Fully tighten the eyebolts, and then loosen them by • Fully tighten the eyebolts, and then loosen them by
a half turn. a half turn.

NM13002-031 NM13002-031

[9] Use a screwdriver to push in the connecting part of [9] Use a screwdriver to push in the connecting part of
the pipe at the bottom of the oil cooler by about 5 the pipe at the bottom of the oil cooler by about 5
cm. cm.

NM13002-032 NM13002-032

[10]Connect the 2 shackles (1) to the eyebolts, and [10]Connect the 2 shackles (1) to the eyebolts, and
then use the wires (2) and crane to lift the oil cooler then use the wires (2) and crane to lift the oil cooler
unit. unit.

2 2

1 1 1 1

NM13002-033 NM13002-033

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


2001-16 2001-16
[11]Thoroughly check that the location is safe before [11]Thoroughly check that the location is safe before
lowering the oil cooler on a crosstie. lowering the oil cooler on a crosstie.
[12] [12]

RM13001-036 RM13001-036

2 Installation of oil cooler 2 Installation of oil cooler


Perform the reverse of the removal procedure. Perform the reverse of the removal procedure.

Lep SM130B2001-0EN Issued 03-08 Lep SM130B2001-0EN Issued 03-08


Section Section
2004 2004

2004

2004
REMOVAL AND INSTALLATION OF THE REMOVAL AND INSTALLATION OF THE
TURBO CHARGER TURBO CHARGER

Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B2004-0EN March 2008 CNH Lep SM130B2004-0EN March 2008
2004-2 2004-2
TABLE OF CONTENTS TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF TURBO CHARGER .................................................................................... 3 REMOVAL AND INSTALLATION OF TURBO CHARGER .................................................................................... 3
REMOVAL OF TURBO CHARGER.............................................................................................................................. 3 REMOVAL OF TURBO CHARGER.............................................................................................................................. 3
INSTALLATION OF TURBO CHARGER ....................................................................................................................... 7 INSTALLATION OF TURBO CHARGER ....................................................................................................................... 7
Tightening torque for each section .................................................................................................................... 7 Tightening torque for each section .................................................................................................................... 7

Lep SM130B2004-0EN Issued 03-08 Lep SM130B2004-0EN Issued 03-08


2004-3 2004-3
REMOVAL AND INSTALLATION OF TURBO CHARGER REMOVAL AND INSTALLATION OF TURBO CHARGER
The turbo charger is extremely hot just after stopping the engine. The turbo charger is extremely hot just after stopping the engine.
Caution: Caution:
Wait for them to sufficiently cool before beginning work. Wait for them to sufficiently cool before beginning work.

Caution: Be sure to stop the engine before beginning work. Caution: Be sure to stop the engine before beginning work.

1 Removal of turbo charger 1 Removal of turbo charger


The engine oil line and coolant line will be removed, so either drain the engine oil and coolant beforehand or use The engine oil line and coolant line will be removed, so either drain the engine oil and coolant beforehand or use
stoppers on the ends of the lines to prevent leaking. stoppers on the ends of the lines to prevent leaking.
[1] Use a wrench (17 mm) to remove the 9 bolts (1), [1] Use a wrench (17 mm) to remove the 9 bolts (1),
and then remove the covers (2) and (3). and then remove the covers (2) and (3).

2 2

1 1

3 3

NF11002-055 NF11002-055

[2] Use a wrench (14 mm) to loosen the nut (5) to [2] Use a wrench (14 mm) to loosen the nut (5) to
remove the 2 bolts (4), remove the seal clamp from remove the 2 bolts (4), remove the seal clamp from
5 5
the exhaust pipe, and then remove the line. the exhaust pipe, and then remove the line.
• Use caps to cover the line to prevent any entry of • Use caps to cover the line to prevent any entry of
water, dust or dirt. water, dust or dirt.
4 4

NF11002-056 NF11002-056

[3] Use a wrench (14 mm) to remove the 2 nuts (6). [3] Use a wrench (14 mm) to remove the 2 nuts (6).

6 NF11002-057 6 NF11002-057

Lep SM130B2004-0EN Issued 03-08 Lep SM130B2004-0EN Issued 03-08


2004-4 2004-4
[4] Remove the U-bolts (7), and then remove the muf- [4] Remove the U-bolts (7), and then remove the muf-
fler (8). fler (8).
7 7
8 8

NF11002-058 NF11002-058

[5] Use a wrench (7 mm) to loosen the hose band (1), [5] Use a wrench (7 mm) to loosen the hose band (1),
and then remove the intake hose (2). and then remove the intake hose (2).
2 2
• Use caps to cover the turbo charger and hose to • Use caps to cover the turbo charger and hose to
prevent any entry of water, dust or dirt. prevent any entry of water, dust or dirt.

1 1

NF11002-081 NF11002-081

[6] Use a wrench (7 mm) to loosen the hose band (3), [6] Use a wrench (7 mm) to loosen the hose band (3),
and then remove the hose (4). and then remove the hose (4).
• Use caps to cover the turbo charger and hose to • Use caps to cover the turbo charger and hose to
prevent any entry of water, dust or dirt. prevent any entry of water, dust or dirt.

3 3

4 NF11002-082 4 NF11002-082

Lep SM130B2004-0EN Issued 03-08 Lep SM130B2004-0EN Issued 03-08


2004-5 2004-5
[7] Use a wrench (14 mm) to remove the eyebolt (5), [7] Use a wrench (14 mm) to remove the eyebolt (5),
and then remove the oil feed pipe (6). and then remove the oil feed pipe (6).
• Use caps and plugs to cover the turbo charger and • Use caps and plugs to cover the turbo charger and
oil feed pipe to prevent any entry of water, dust or oil feed pipe to prevent any entry of water, dust or
dirt. 5 dirt. 5
6 6
• When removing the oil feed pipe, take care not to • When removing the oil feed pipe, take care not to
damage or lose the packing. damage or lose the packing.

NF11002-084 NF11002-084

[8] Use a wrench (17 mm) to remove the eyebolt (7), [8] Use a wrench (17 mm) to remove the eyebolt (7),
and then remove the water return pipe (8). and then remove the water return pipe (8).
7 7
• Use caps and plugs to cover the turbo charger and • Use caps and plugs to cover the turbo charger and
water return pipe to prevent any entry of water, dust water return pipe to prevent any entry of water, dust
or dirt. or dirt.

8 8

NF11002-085 NF11002-085

[9] Use a wrench (17 mm) to remove the eyebolt (9), [9] Use a wrench (17 mm) to remove the eyebolt (9),
and then remove the water feed pipe (10). 10 and then remove the water feed pipe (10). 10
• Use caps and plugs to cover the turbo charger and • Use caps and plugs to cover the turbo charger and
water feed pipe to prevent any entry of water, dust water feed pipe to prevent any entry of water, dust
or dirt. or dirt.

9 9

NF11002-086 NF11002-086

[10]Use a wrench (10 mm) to remove the 2 bolts (11), [10]Use a wrench (10 mm) to remove the 2 bolts (11),
and then remove the oil return pipe (12). and then remove the oil return pipe (12).
• Use caps and plugs to cover the turbo charger and • Use caps and plugs to cover the turbo charger and
oil return pipe to prevent any entry of water, dust or oil return pipe to prevent any entry of water, dust or
dirt. dirt.
12 12

11 11

NF11002-087 NF11002-087

Lep SM130B2004-0EN Issued 03-08 Lep SM130B2004-0EN Issued 03-08


2004-6 2004-6
[11]Use a wrench (14 mm) to remove the 4 nuts (13), [11]Use a wrench (14 mm) to remove the 4 nuts (13),
and then remove the turbo charger (14). and then remove the turbo charger (14).

13 13

14 14

NF11002-088 NF11002-088

[12]Use a wrench (13 mm) to remove the 8 nuts (15), [12]Use a wrench (13 mm) to remove the 8 nuts (15),
and then remove the line (16) from the turbo and then remove the line (16) from the turbo
charger. charger.

15 15

16 NF11002-089
16 NF11002-089

Lep SM130B2004-0EN Issued 03-08 Lep SM130B2004-0EN Issued 03-08


2004-7 2004-7
2 Installation of turbo charger 2 Installation of turbo charger
To install, perform the reverse of the removal procedure. During installation, replace each gasket and the packing To install, perform the reverse of the removal procedure. During installation, replace each gasket and the packing
with new ones. with new ones.
Make sure to check the engine oil and coolant levels and resupply as necessary. Make sure to check the engine oil and coolant levels and resupply as necessary.
Each of the installation tightening torque values are indicated below. Each of the installation tightening torque values are indicated below.
Check carefully for exhaust leaks, water leaks, and oil leaks. Check carefully for exhaust leaks, water leaks, and oil leaks.

6 7 1 Turbo charger assembly 35 Nm 6 7 1 Turbo charger assembly 35 Nm


2 Exhaust adapter 35 Nm 2 Exhaust adapter 35 Nm
3 Oil return pipe 10 Nm 3 Oil return pipe 10 Nm
4 Oil feed pipe 22.5 Nm 4 Oil feed pipe 22.5 Nm
5 Exhaust manifold 52 Nm 5 Exhaust manifold 52 Nm
6 Water feed pipe 22.5 Nm 6 Water feed pipe 22.5 Nm
7 Water return pipe 22.5 Nm 7 Water return pipe 22.5 Nm

5 4 3 2 1 NF11002-090 5 4 3 2 1 NF11002-090

1 Tightening torque for each section 1 Tightening torque for each section
Unit: Nm Unit: Nm

10 10

22.5 22.5

22.5 10 22.5 10

10 10
35 35 35 35

22.5 22.5

35 35

25 25
NF11002-091 NF11002-091

Lep SM130B2004-0EN Issued 03-08 Lep SM130B2004-0EN Issued 03-08


2004-8 2004-8
NOTES NOTES
........................................................................................................................................................................................ ........................................................................................................................................................................................
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Lep SM130B2004-0EN Issued 03-08 Lep SM130B2004-0EN Issued 03-08


Section Section
2005 2005

REMOVAL AND INSTALLATION OF THE REMOVAL AND INSTALLATION OF THE


EGR COOLER AND EGR VALVE EGR COOLER AND EGR VALVE

2005

2005
Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B2005-0EN March 2008 CNH Lep SM130B2005-0EN March 2008
2005-2 2005-2
TABLE OF CONTENTS TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF EGR COOLER AND EGR VALVE ............................................................. 3 REMOVAL AND INSTALLATION OF EGR COOLER AND EGR VALVE ............................................................. 3
REMOVAL OF EGR COOLER AND EGR VALVE ........................................................................................................ 3 REMOVAL OF EGR COOLER AND EGR VALVE ........................................................................................................ 3
INSTALLATION OF EGR COOLER AND EGR VALVE ................................................................................................. 4 INSTALLATION OF EGR COOLER AND EGR VALVE ................................................................................................. 4
Tightening torque for each section .................................................................................................................... 4 Tightening torque for each section .................................................................................................................... 4

Lep SM130B2005-0EN Issued 03-08 Lep SM130B2005-0EN Issued 03-08


2005-3 2005-3
REMOVAL AND INSTALLATION OF EGR COOLER AND EGR VALVE REMOVAL AND INSTALLATION OF EGR COOLER AND EGR VALVE
The EGR cooler and EGR valve are extremely hot just after stopping the engine. The EGR cooler and EGR valve are extremely hot just after stopping the engine.
Caution: Caution:
Wait for them to sufficiently cool before beginning work. Wait for them to sufficiently cool before beginning work.

Be sure to stop the engine before beginning work. Be sure to stop the engine before beginning work.
Caution: Caution:
Be sure to drain coolant before beginning work. Be sure to drain coolant before beginning work.
1 Removal of EGR cooler and EGR valve 1 Removal of EGR cooler and EGR valve
[1] Use a wrench (10 mm) to remove the bolt (1) secur- [1] Use a wrench (10 mm) to remove the bolt (1) secur-
ing the turbocharger water feed pipe bracket to the ing the turbocharger water feed pipe bracket to the
EGR cooler. EGR cooler.

1 1

NF11002-071 NF11002-071

[2] Use pliers to loosen the hose bands (2) and (3), and [2] Use pliers to loosen the hose bands (2) and (3), and
then remove the hoses (4) and (5). then remove the hoses (4) and (5).
• Use caps and plugs to cover the line hoses to pre- • Use caps and plugs to cover the line hoses to pre-
vent any entry of water, dust or dirt. vent any entry of water, dust or dirt.
5 5

3 3

2 4 2 4
NF11002-072 NF11002-072

[3] Use a wrench (13 mm) to remove the manifold (6) [3] Use a wrench (13 mm) to remove the manifold (6)
and EGR cooler (7) installation bolts (8). and EGR cooler (7) installation bolts (8).

7 6 8 7 6 8
NF11002-073 NF11002-073

Lep SM130B2005-0EN Issued 03-08 Lep SM130B2005-0EN Issued 03-08


2005-4 2005-4
[4] Use a wrench (12 mm) to remove the nut (9) and [4] Use a wrench (12 mm) to remove the nut (9) and
another wrench (14 mm) to remove the bolt (10), another wrench (14 mm) to remove the bolt (10),
and remove the EGR cooler. and remove the EGR cooler.

9 10 NF11002-074 9 10 NF11002-074

2 Installation of EGR cooler and EGR valve 2 Installation of EGR cooler and EGR valve
To install, perform the reverse of the removal procedure. During installation, replace gaskets with new ones. To install, perform the reverse of the removal procedure. During installation, replace gaskets with new ones.
Check that there is sufficient coolant and resupply as necessary. Each of the installation tightening torque values are Check that there is sufficient coolant and resupply as necessary. Each of the installation tightening torque values are
indicated below. indicated below.
Check carefully for exhaust leaks and water leaks. Check carefully for exhaust leaks and water leaks.
1 Tightening torque for each section 1 Tightening torque for each section
Unit: Nm Unit: Nm

24 24 24 24

24 24

28 28

24 24
28 28
RF11001-114 RF11001-114

Lep SM130B2005-0EN Issued 03-08 Lep SM130B2005-0EN Issued 03-08


Section Section
2006 2006

REMOVAL AND INSTALLATION OF THE REMOVAL AND INSTALLATION OF THE


ENGINE HOOD ENGINE HOOD

2006

2006
Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B2006-0EN March 2008 CNH Lep SM130B2006-0EN March 2008
2006-2 2006-2
TABLE OF CONTENTS TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF ENGINE HOOD........................................................................................... 3 REMOVAL AND INSTALLATION OF ENGINE HOOD........................................................................................... 3
REMOVAL ............................................................................................................................................................. 3 REMOVAL ............................................................................................................................................................. 3
INSTALLATION ....................................................................................................................................................... 4 INSTALLATION ....................................................................................................................................................... 4

Lep SM130B2006-0EN Issued 03-08 Lep SM130B2006-0EN Issued 03-08


2006-3 2006-3
REMOVAL AND INSTALLATION OF ENGINE HOOD REMOVAL AND INSTALLATION OF ENGINE HOOD

Be sure to stop the engine before beginning work. Be sure to stop the engine before beginning work.
Do not perform this operation in strong wind. Do not perform this operation in strong wind.
Caution: Caution:
Be sure to inspect the wire rope and other lifting equipment before beginning work. Be sure to inspect the wire rope and other lifting equipment before beginning work.
Do not stand or pass under the suspended load. Do not stand or pass under the suspended load.
1 Removal 1 Removal
[1] Open the engine hood, and then remove the snap [1] Open the engine hood, and then remove the snap
pin (1) and the flat washer (2). pin (1) and the flat washer (2).

1 1

2 2

NF11002-001 NF11002-001

[2] Pull out the locking arm (4) from the engine hood [2] Pull out the locking arm (4) from the engine hood
(3). (3).

3 3

4 4

NF11002-002 NF11002-002

3 3

4 4

NF11002-003 NF11002-003

Lep SM130B2006-0EN Issued 03-08 Lep SM130B2006-0EN Issued 03-08


2006-4 2006-4
[3] After closing the engine hood, disassemble the [3] After closing the engine hood, disassemble the
retaining screws (5) from the engine hood. retaining screws (5) from the engine hood.

5 5

NF11002-004 NF11002-004

[4] Wrap the nylon sling (6) around the engine hood, [4] Wrap the nylon sling (6) around the engine hood,
and then use the crane to lift the engine hood. and then use the crane to lift the engine hood.

6 6

NF11002-005 NF11002-005

2 Installation 2 Installation
To install, perform the reverse of the removal procedure. To install, perform the reverse of the removal procedure.

Lep SM130B2006-0EN Issued 03-08 Lep SM130B2006-0EN Issued 03-08


3001

3001
Section Section
3001 3001

REMOVAL AND INSTALLATION OF THE REMOVAL AND INSTALLATION OF THE


FUEL TANK FUEL TANK

Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B3001-0EN March 2008 CNH Lep SM130B3001-0EN March 2008
3001-2 3001-2
TABLE OF CONTENTS TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF FUEL TANK ................................................................................................ 3 REMOVAL AND INSTALLATION OF FUEL TANK ................................................................................................ 3
REMOVAL OF FUEL TANK ....................................................................................................................................... 3 REMOVAL OF FUEL TANK ....................................................................................................................................... 3
INSTALLATION OF FUEL TANK ................................................................................................................................ 7 INSTALLATION OF FUEL TANK ................................................................................................................................ 7

Lep SM130B3001-0EN Issued 03-08 Lep SM130B3001-0EN Issued 03-08


3001-3 3001-3
REMOVAL AND INSTALLATION OF FUEL TANK REMOVAL AND INSTALLATION OF FUEL TANK
Caution: Keep away from fire. Caution: Keep away from fire.

Be sure to stop the engine before beginning work. Be sure to stop the engine before beginning work.
Caution: Be sure to inspect the wire rope and other lifting equipment before beginning work. Caution: Be sure to inspect the wire rope and other lifting equipment before beginning work.
Do not stand or pass under the suspended load. Do not stand or pass under the suspended load.
1 Removal of fuel tank 1 Removal of fuel tank
[1] Remove the cap (1) and filter (2). [1] Remove the cap (1) and filter (2).
1 1

2 2

RM14001-021 RM14001-021

[2] Drain out all the fuel from the fuel tank into a [2] Drain out all the fuel from the fuel tank into a
drum can. drum can.

RM14001-022 RM14001-022

Lep SM130B3001-0EN Issued 03-08 Lep SM130B3001-0EN Issued 03-08


3001-4 3001-4
[3] Use the drain cock (1) on the bottom of the tank to [3] Use the drain cock (1) on the bottom of the tank to
drain out any fuel that does not drain out but drain out any fuel that does not drain out but
remains at the bottom of the tank. remains at the bottom of the tank.

1 1

NM14002-015 NM14002-015

[4] Disassemble the retaining screws (1), and then [4] Disassemble the retaining screws (1), and then
remove the top cover (2). remove the top cover (2).
1 2 1 2

NM14002-016 NM14002-016

[5] Disassemble the retaining screws (1), and then [5] Disassemble the retaining screws (1), and then
remove the cover (2). remove the cover (2).
2 1 2 1

RM14001-024 RM14001-024

Lep SM130B3001-0EN Issued 03-08 Lep SM130B3001-0EN Issued 03-08


3001-5 3001-5
[6] Disassemble the retaining screws (1) and (2), [6] Disassemble the retaining screws (1) and (2),
clamps (4), and then remove the handle (3). 3 4 clamps (4), and then remove the handle (3). 3 4

1 1

2 2

4 4

RM14001-025 RM14001-025

[7] Disassemble the retaining screws (1) and (2), and [7] Disassemble the retaining screws (1) and (2), and
then remove the side cover (3). then remove the side cover (3).

3 3

1 1

RM14001-026 RM14001-026

3 3

2 2

RM14001-027 RM14001-027

[8] Disassemble the retaining screws (1), and then [8] Disassemble the retaining screws (1), and then
remove the under cover (2). remove the under cover (2).

2 1 2 1

NM14002-017 NM14002-017

Lep SM130B3001-0EN Issued 03-08 Lep SM130B3001-0EN Issued 03-08


3001-6 3001-6
[9] Loosen the hoseband (1), and then remove the hose [9] Loosen the hoseband (1), and then remove the hose
(2). (2).
• Mark the fuel tank and hoses so that they can be • Mark the fuel tank and hoses so that they can be
connected correctly at the time of assembly. connected correctly at the time of assembly.
• Attach caps or plugs to the fuel tank and hoses to • Attach caps or plugs to the fuel tank and hoses to
prevent entry of water, dust or dirt. prevent entry of water, dust or dirt.
1 1
2 2

NM14002-018 NM14002-018

[10]Remove the connector (1). [10]Remove the connector (1).

1 1

NM14002-019 NM14002-019

[11]Disassemble the retaining screws (1) and collars (2) [11]Disassemble the retaining screws (1) and collars (2)
from the bottom of the fuel tank. from the bottom of the fuel tank.
• Depending on the machine, there may be height 2 • Depending on the machine, there may be height 2
adjustment shims between the tank and the frame. adjustment shims between the tank and the frame.
1 1
Do not lose them. Also, mark or write down the loca- Do not lose them. Also, mark or write down the loca-
tion where they are and how many. tion where they are and how many.

NM14002-020 NM14002-020

[12]Disassemble the retaining screws (1) and (2), and [12]Disassemble the retaining screws (1) and (2), and
then remove the side cover (3). 3 then remove the side cover (3). 3
3 3

2 2
1 1

NM14002-021 NM14002-021

Lep SM130B3001-0EN Issued 03-08 Lep SM130B3001-0EN Issued 03-08


3001-7 3001-7
[13]Install 4 12-mm eyebolts (1) on top of the fuel tank. [13]Install 4 12-mm eyebolts (1) on top of the fuel tank.
Spray lubricating oil on the eyebolts. Spray lubricating oil on the eyebolts.
• Fully tighten the eyebolts, and then loosen them by • Fully tighten the eyebolts, and then loosen them by
a half turn. 1 a half turn. 1

NM14002-022 NM14002-022

[14]Connect the 4 shackles to the eyebolts, and then [14]Connect the 4 shackles to the eyebolts, and then
use the wires and crane to lift the fuel tank. use the wires and crane to lift the fuel tank.
[15]Thoroughly check that the location is safe before [15]Thoroughly check that the location is safe before
lowering the fuel tank on a crosstie. lowering the fuel tank on a crosstie.

NM14002-023 NM14002-023

2 Installation of fuel tank 2 Installation of fuel tank


When installing, perform the reverse of the removal When installing, perform the reverse of the removal
procedure. procedure.
Finally, carefully check for any fuel leaks. Finally, carefully check for any fuel leaks.

Lep SM130B3001-0EN Issued 03-08 Lep SM130B3001-0EN Issued 03-08


3001-8 3001-8
NOTES NOTES
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Lep SM130B3001-0EN Issued 03-08 Lep SM130B3001-0EN Issued 03-08


Section Section
3004 3004

3004

3004
REMOVAL AND INSTALLATION OF THE REMOVAL AND INSTALLATION OF THE
SUPPLY PUMP & COMMON RAIL SUPPLY PUMP & COMMON RAIL

Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B3004-0EN March 2008 CNH Lep SM130B3004-0EN March 2008
3004-2 3004-2
TABLE OF CONTENTS TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF SUPPLY PUMP .......................................................................................... 3 REMOVAL AND INSTALLATION OF SUPPLY PUMP .......................................................................................... 3
REMOVAL OF SUPPLY PUMP................................................................................................................................... 3 REMOVAL OF SUPPLY PUMP................................................................................................................................... 3
INSTALLATION OF SUPPLY PUMP ............................................................................................................................ 8 INSTALLATION OF SUPPLY PUMP ............................................................................................................................ 8
REMOVAL AND INSTALLATION OF COMMON RAIL ........................................................................................ 13 REMOVAL AND INSTALLATION OF COMMON RAIL ........................................................................................ 13
REMOVAL OF COMMON RAIL ................................................................................................................................ 13 REMOVAL OF COMMON RAIL ................................................................................................................................ 13
INSTALLATION OF COMMON RAIL .......................................................................................................................... 15 INSTALLATION OF COMMON RAIL .......................................................................................................................... 15

Lep SM130B3004-0EN Issued 03-08 Lep SM130B3004-0EN Issued 03-08


3004-3 3004-3
REMOVAL AND INSTALLATION OF SUPPLY PUMP REMOVAL AND INSTALLATION OF SUPPLY PUMP
Caution: Be sure to release hydraulic pressure before beginning work. Caution: Be sure to release hydraulic pressure before beginning work.

Caution: Be sure to stop the engine before beginning work. Caution: Be sure to stop the engine before beginning work.

Each part of the fuel system is a high-precision part. Each part of the fuel system is a high-precision part.
Caution: Damage may result if foreign matter, ect. enters the fuel system, so use extreme Caution: Damage may result if foreign matter, ect. enters the fuel system, so use extreme
caution when handling these parts. caution when handling these parts.

When high-pressure lines in the fuel system are removed, replace them with new When high-pressure lines in the fuel system are removed, replace them with new
lines. lines.
Caution: Replace gaskets or O-rings with new ones Caution: Replace gaskets or O-rings with new ones
Fuel leaks may cause fires. Thoroughly wipe off fuel after work is completed, and Fuel leaks may cause fires. Thoroughly wipe off fuel after work is completed, and
carefully check for any leaks after starting the engine. carefully check for any leaks after starting the engine.
1 Removal of supply pump 1 Removal of supply pump
[1] Use a wrench (10 mm) to remove the bolt (1), and [1] Use a wrench (10 mm) to remove the bolt (1), and
then remove the hole cover (2). then remove the hole cover (2).

2 2

1 RF11001-045
1 RF11001-045

[2] Turn the crankshaft in the correct rotation direction [2] Turn the crankshaft in the correct rotation direction
and align the reference mark of the 1st or 4th cylin- and align the reference mark of the 1st or 4th cylin-
der with the compression top dead center position. der with the compression top dead center position.

RF11001-047 RF11001-047

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3004-4 3004-4
[3] Use a wrench (8 mm) to loosen the hose bands (3), [3] Use a wrench (8 mm) to loosen the hose bands (3),
and then remove the air hose (4). and then remove the air hose (4).
3 4 3 3 4 3
• Use caps and plugs to cover the hose and line to • Use caps and plugs to cover the hose and line to
prevent any entry of water, dust or dirt. prevent any entry of water, dust or dirt.

RF11001-048 RF11001-048

[4] Remove the connector (5). [4] Remove the connector (5).

5 RF11001-049 5 RF11001-049

[5] Use a wrench (12 mm) to remove the 3 bolts (6), [5] Use a wrench (12 mm) to remove the 3 bolts (6),
and then remove the inlet pipe (7). 7 and then remove the inlet pipe (7). 7
• Cover the line to prevent the entry of water, dust or • Cover the line to prevent the entry of water, dust or
dirt. dirt.
• Clean the line by spraying with a parts cleaner to • Clean the line by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumulat- prevent scratches and prevent dirt from accumulat-
ing on the connectors. 6 ing on the connectors. 6

6 6 RF11001-050 6 6 RF11001-050

[6] Use a wrench (10 mm) to remove the bolts (6) on [6] Use a wrench (10 mm) to remove the bolts (6) on
the clamps (8). 10 9 the clamps (8). 10 9
[7] Remove the connectors (9) and (10). [7] Remove the connectors (9) and (10).

8 8

6 RF11001-052 6 RF11001-052

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3004-5 3004-5
[8] Use a hexagon wrench (4 mm) to remove the bolt [8] Use a hexagon wrench (4 mm) to remove the bolt
(11) on the clamp (12). 11 (11) on the clamp (12). 11
12 12

RF11001-053 RF11001-053

[9] Use a wrench (12 mm) to remove the bolt (13), and [9] Use a wrench (12 mm) to remove the bolt (13), and
then remove the oil gauge line (14). 13 then remove the oil gauge line (14). 13
• Use caps and plugs to cover the line to prevent any • Use caps and plugs to cover the line to prevent any
entry of water, dust or dirt. entry of water, dust or dirt.
• Clean the line by spraying with a parts cleaner to • Clean the line by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumulat- 14 prevent scratches and prevent dirt from accumulat- 14
ing on the connectors. ing on the connectors.

13 RF11001-054 13 RF11001-054

[10]Use a wrench (19 mm) to remove the sleeve nuts [10]Use a wrench (19 mm) to remove the sleeve nuts
(15), and then remove the injection pipe (16). (15), and then remove the injection pipe (16).
• Use caps and plugs to cover the line to prevent any • Use caps and plugs to cover the line to prevent any
entry of water, dust or dirt. entry of water, dust or dirt.
• Clean the line by spraying with a parts cleaner to 15 • Clean the line by spraying with a parts cleaner to 15
prevent scratches and prevent dirt from accumulat- prevent scratches and prevent dirt from accumulat-
ing on the connectors. ing on the connectors.

16 16

15 RF11001-055
15 RF11001-055

[11]Remove the fuel hose (17). [11]Remove the fuel hose (17).
• Use caps and plugs to cover the line to prevent any • Use caps and plugs to cover the line to prevent any
entry of water, dust or dirt. entry of water, dust or dirt.

17 17

RF11001-056 RF11001-056

Lep SM130B3004-0EN Issued 03-08 Lep SM130B3004-0EN Issued 03-08


3004-6 3004-6
[12]Use a wrench (10 mm) to remove the bolt (19) on [12]Use a wrench (10 mm) to remove the bolt (19) on
the leak-off pipe (20). 18 20 the leak-off pipe (20). 18 20
[13]Use a wrench (12 mm) to remove the eye bolt (18) [13]Use a wrench (12 mm) to remove the eye bolt (18)
on the leak-off pipe (20). on the leak-off pipe (20).
19 19

RF11001-057 RF11001-057

[14]Use a wrench (14 mm) to remove the eyebolts (21) [14]Use a wrench (14 mm) to remove the eyebolts (21)
and (22) on the leak-off pipe (20). and (22) on the leak-off pipe (20).

21 20 22 21 20 22
RF11001-058 RF11001-058

[15]Remove the leak-off pipe (20). [15]Remove the leak-off pipe (20).
• Use caps and plugs to cover the line to prevent any • Use caps and plugs to cover the line to prevent any
entry of water, dust or dirt. entry of water, dust or dirt.
• Clean the line by spraying with a parts cleaner to • Clean the line by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumulat- prevent scratches and prevent dirt from accumulat-
ing on the connectors. ing on the connectors.

20 20
RF11001-059 RF11001-059

[16]Remove the connectors (23) and (24). [16]Remove the connectors (23) and (24).
[17]Use a wrench (22 mm) to remove the eyebolt (25) [17]Use a wrench (22 mm) to remove the eyebolt (25)
on the fuel pipe (26). on the fuel pipe (26).

23 23

24 24

25 25
26 RF11001-060 26 RF11001-060

Lep SM130B3004-0EN Issued 03-08 Lep SM130B3004-0EN Issued 03-08


3004-7 3004-7
[18]Use a wrench (14 mm) to remove the nuts (27). [18]Use a wrench (14 mm) to remove the nuts (27).
[19]Use a wrench (17 mm) to remove the bolts (28) and 30 29 [19]Use a wrench (17 mm) to remove the bolts (28) and 30 29
(29). 27 (29). 27
[20]Remove the supply pump assembly (30). [20]Remove the supply pump assembly (30).
• Use caps and plugs to prevent any entry of water, • Use caps and plugs to prevent any entry of water,
dust or dirt. dust or dirt.
• Clean the assembly by spraying it with a parts 27 • Clean the assembly by spraying it with a parts 27
cleaner to prevent scratches and prevent dirt from cleaner to prevent scratches and prevent dirt from
accumulating on the connectors. accumulating on the connectors.

28 28
RF11001-061 RF11001-061

30 30

RF11001-062 RF11001-062

[21]Remove the nut securing the supply pump gear [21]Remove the nut securing the supply pump gear
(31) and use the gear puller (32) to remove the gear (31) and use the gear puller (32) to remove the gear
30 30
from the supply pump assembly (30). 32 from the supply pump assembly (30). 32

31 31
RF11001-097 RF11001-097

[22]Remove the 3 bolts (36), and then remove the sup- [22]Remove the 3 bolts (36), and then remove the sup-
ply pump (33). Also remove the O-ring (34) at the 35 ply pump (33). Also remove the O-ring (34) at the 35
same time. 34 same time. 34
33 33

36 36

RF11001-098 RF11001-098

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3004-8 3004-8
2 Installation of supply pump 2 Installation of supply pump
[1] Install the O-ring (2) on the supply pump (1). [1] Install the O-ring (2) on the supply pump (1).
Install the pump on the bracket (3) and tighten the 3 3 Install the pump on the bracket (3) and tighten the 3 3
bolts (4) to the specified torque. 2 bolts (4) to the specified torque. 2
Tightening torque: 19 Nm. Tightening torque: 19 Nm.
1 1

4 4

RF11001-099 RF11001-099

[2] Align the key of the supply pump shaft with the gear [2] Align the key of the supply pump shaft with the gear
(5), install the gear, and tighten the nut (6) to the (5), install the gear, and tighten the nut (6) to the
specified torque. specified torque.
Tightening torque: 64 Nm. Tightening torque: 64 Nm.
6 6

5 5
RF11001-100 RF11001-100

[3] A reference mark circle has been stamped onto the [3] A reference mark circle has been stamped onto the
end face surface of the gear. end face surface of the gear.
Paint the upper part of the gear tooth just above the Paint the upper part of the gear tooth just above the
stamped "0" mark white. stamped "0" mark white.
This paint is very important for checking the correct This paint is very important for checking the correct
position. position.

RF11001-101 RF11001-101

Lep SM130B3004-0EN Issued 03-08 Lep SM130B3004-0EN Issued 03-08


3004-9 3004-9
[4] Install the O-ring (7) on the supply pump assembly [4] Install the O-ring (7) on the supply pump assembly
(8). (8).
Align the supply pump gear position with the refer- Align the supply pump gear position with the refer-
ence mark (0 mark) on the gear end face surface ence mark (0 mark) on the gear end face surface
and the slit on the pump bracket side. and the slit on the pump bracket side.
Install the supply pump assembly on the engine so Install the supply pump assembly on the engine so
that the alignment position is correct. that the alignment position is correct.
Temporarily tighten the bolts (10) and (11) and the 9 Temporarily tighten the bolts (10) and (11) and the 9
nut (9). nut (9).

11 11

7 7

8 10 RF11001-102 8 10 RF11001-102

[5] When looking from the plug hole, check that the [5] When looking from the plug hole, check that the
gear tooth with the reference mark (0 mark) and gear tooth with the reference mark (0 mark) and
white paint is at the center of the hole and in the white paint is at the center of the hole and in the
position shown in the diagram. position shown in the diagram.
If alignment is not correct, adjust the gear position If alignment is not correct, adjust the gear position
again and install the pump on it. again and install the pump on it.
Temporarily tighten bolts (10) and (11) and nut (9) to Temporarily tighten bolts (10) and (11) and nut (9) to
the specified torque. A the specified torque. A
Tightening torque B Tightening torque B
Nut: 50 Nm Nut: 50 Nm
Bolt: 76 Nm Bolt: 76 Nm

A A

B B

RF11001-103 RF11001-103

[6] Install the hole cover (13) in the plug hole. [6] Install the hole cover (13) in the plug hole.
Tighten the bolt (12) to the specified torque. Tighten the bolt (12) to the specified torque.
Tightening torque: 8 Nm Tightening torque: 8 Nm

13 13

12 RF11001-127 12 RF11001-127

Lep SM130B3004-0EN Issued 03-08 Lep SM130B3004-0EN Issued 03-08


3004-10 3004-10
[7] Connect the connectors (14) and (15). [7] Connect the connectors (14) and (15).
Install the line (17) with the eyebolt (16). Install the line (17) with the eyebolt (16).

14 14

15 15

16 16
17 RF11001-128 17 RF11001-128

[8] Install the leak-off pipe (18) with eyebolts (19), (21) [8] Install the leak-off pipe (18) with eyebolts (19), (21)
and (22) and bolt (20). 19 18 and (22) and bolt (20). 19 18
• Be careful not to allow entry of any water, dust or • Be careful not to allow entry of any water, dust or
dirt. dirt.
• Clean the line by spraying with a parts cleaner to 20 • Clean the line by spraying with a parts cleaner to 20
prevent scratches and prevent dirt from accumulat- prevent scratches and prevent dirt from accumulat-
ing on the connectors. ing on the connectors.
Always replace seals. Always replace seals.

RF11001-129 RF11001-129

21 18 22 21 18 22
RF11001-130 RF11001-130

[9] Install the fuel hose (23). [9] Install the fuel hose (23).
• Be careful not to allow entry of any water, dust or • Be careful not to allow entry of any water, dust or
dirt. dirt.

23 23

RF11001-131 RF11001-131

Lep SM130B3004-0EN Issued 03-08 Lep SM130B3004-0EN Issued 03-08


3004-11 3004-11
[10]Install the injection pipe (25). This injection pipe [10]Install the injection pipe (25). This injection pipe
cannot be reused, so always replace it with a new cannot be reused, so always replace it with a new
one. one.
Tighten the sleeve nuts (24). Tighten the sleeve nuts (24).
• Be careful not to allow entry of any water, dust or 24 • Be careful not to allow entry of any water, dust or 24
dirt. dirt.
• Clean the line by spraying with a parts cleaner to • Clean the line by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumulat- prevent scratches and prevent dirt from accumulat-
ing on the connectors. ing on the connectors.

25 25

24 RF11001-132 24 RF11001-132

[11]Install the clamp (27) with the bolt (26). [11]Install the clamp (27) with the bolt (26).
26 26
27 27

RF11001-133 RF11001-133

[12]Install the oil gauge line (29) with the bolts (28). [12]Install the oil gauge line (29) with the bolts (28).
• Be careful not to allow entry of any water, dust or 28 • Be careful not to allow entry of any water, dust or 28
dirt. dirt.
• Clean the line by spraying with a parts cleaner to • Clean the line by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumulat- prevent scratches and prevent dirt from accumulat-
ing on the connectors. 29 ing on the connectors. 29

28 RF11001-134 28 RF11001-134

[13]Install each wiring clamp (33) with a bolt (32) and [13]Install each wiring clamp (33) with a bolt (32) and
install the wiring connectors (30) and (31). 31 30 install the wiring connectors (30) and (31). 31 30

32 33 RF11001-135 32 33 RF11001-135

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3004-12 3004-12
[14]Install the inlet pipe (35) with the 3 bolts (34) and [14]Install the inlet pipe (35) with the 3 bolts (34) and
tighten to the specified torque. 35 tighten to the specified torque. 35
Tightening torque: 24 Nm Tightening torque: 24 Nm

34 34

34 34 RF11001-136 34 34 RF11001-136

[15]Connect the connector (36). [15]Connect the connector (36).

36 RF11001-137 36 RF11001-137

[16]Install the air hose (38), and tighten the hose bands [16]Install the air hose (38), and tighten the hose bands
(37). (37).
37 38 37 37 38 37
• Be careful not to allow entry of any water, dust or • Be careful not to allow entry of any water, dust or
dirt. dirt.

RF11001-138 RF11001-138

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3004-13 3004-13
REMOVAL AND INSTALLATION OF COMMON RAIL REMOVAL AND INSTALLATION OF COMMON RAIL

Caution: Be sure to stop the engine before beginning work. Caution: Be sure to stop the engine before beginning work.

1 Removal of common rail 1 Removal of common rail


See "Removal and Installation of Supply Pump" for procedures for removal and installation of the oil level gauge See "Removal and Installation of Supply Pump" for procedures for removal and installation of the oil level gauge
pipe, intake hose, manifold, etc. pipe, intake hose, manifold, etc.
[1] Remove the connector (1). [1] Remove the connector (1).

1 RF11001-039
1 RF11001-039

[2] Use a wrench (12 mm) to remove the bolts (2) on [2] Use a wrench (12 mm) to remove the bolts (2) on
the wiring clamp. the wiring clamp.
[3] Use a wrench (10 mm) to remove the bolts (3) on [3] Use a wrench (10 mm) to remove the bolts (3) on
the wiring clamp. the wiring clamp.

2 2
3 3
3 RF11001-040 3 RF11001-040

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3004-14 3004-14
[4] Use a wrench (14 mm) to remove the eyebolts (4) [4] Use a wrench (14 mm) to remove the eyebolts (4)
and (5) on the leak-off pipe (6), and remove the and (5) on the leak-off pipe (6), and remove the
leak-off pipe. leak-off pipe.

4 6 5 RF11001-041
4 6 5 RF11001-041

[5] Use a wrench (10 mm) to remove the nuts (8) on the [5] Use a wrench (10 mm) to remove the nuts (8) on the
line clamps (7). 8 7 8 7 7 8 line clamps (7). 8 7 8 7 7 8
[6] Use a wrench (17 mm) to remove each sleeve nut [6] Use a wrench (17 mm) to remove each sleeve nut
(9) in the 4 locations. (9) in the 4 locations.
• Replace the removed line in the same way as the • Replace the removed line in the same way as the
common rail. common rail.
• Use caps and plugs to cover the line to prevent any • Use caps and plugs to cover the line to prevent any
entry of water, dust or dirt. entry of water, dust or dirt.
• Clean the line by spraying with a parts cleaner to • Clean the line by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumulat- prevent scratches and prevent dirt from accumulat-
ing on the connectors. ing on the connectors.

9 RF11001-042
9 RF11001-042

[7] Use a wrench (12 mm) to remove bolts (11) and (12) [7] Use a wrench (12 mm) to remove bolts (11) and (12)
and nuts (10). and nuts (10).

10 10
11 11
10 10
12 RF11001-043 12 RF11001-043

Lep SM130B3004-0EN Issued 03-08 Lep SM130B3004-0EN Issued 03-08


3004-15 3004-15
[8] Remove the common rail (13). [8] Remove the common rail (13).
13 13

RF11001-044 RF11001-044

2 Installation of common rail 2 Installation of common rail


[1] To install the common rail, perform the reverse of [1] To install the common rail, perform the reverse of
the removal procedure. the removal procedure.
High-pressure lines that have been removed cannot High-pressure lines that have been removed cannot
be reused. be reused.
Always replace them with new ones. Always replace them with new ones.

Lep SM130B3004-0EN Issued 03-08 Lep SM130B3004-0EN Issued 03-08


3004-16 3004-16
NOTES NOTES
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Lep SM130B3004-0EN Issued 03-08 Lep SM130B3004-0EN Issued 03-08


Section Section
3005 3005

REMOVAL AND INSTALLATION OF THE REMOVAL AND INSTALLATION OF THE


INJECTORS INJECTORS

3005

3005
Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B3005-0EN March 2008 CNH Lep SM130B3005-0EN March 2008
3005-2 3005-2
TABLE OF CONTENTS TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF INJECTOR .................................................................................................. 3 REMOVAL AND INSTALLATION OF INJECTOR .................................................................................................. 3
REMOVAL OF INJECTOR ......................................................................................................................................... 3 REMOVAL OF INJECTOR ......................................................................................................................................... 3
INSTALLATION OF INJECTOR .................................................................................................................................. 8 INSTALLATION OF INJECTOR .................................................................................................................................. 8

Lep SM130B3005-0EN Issued 03-08 Lep SM130B3005-0EN Issued 03-08


3005-3 3005-3
REMOVAL AND INSTALLATION OF INJECTOR REMOVAL AND INSTALLATION OF INJECTOR
Caution: Do not use open flames and do not allow sparks near the battery. Caution: Do not use open flames and do not allow sparks near the battery.

Caution: Injector wiring are high voltage wirings, so make sure to remove the battery. Caution: Injector wiring are high voltage wirings, so make sure to remove the battery.

Caution: Be sure to stop the engine before beginning work. Caution: Be sure to stop the engine before beginning work.

Caution: Be careful not to drop any removed parts inside the engine. Caution: Be careful not to drop any removed parts inside the engine.

1 Removal of injector 1 Removal of injector


Removal and installation of the No. 1 injector is explained here as a representative example. Use the same proce- Removal and installation of the No. 1 injector is explained here as a representative example. Use the same proce-
dure for other cylinder injectors. dure for other cylinder injectors.
Be extremely careful when handling injectors. The nozzle tips are especially delicate. Hitting the nozzles or wiping Be extremely careful when handling injectors. The nozzle tips are especially delicate. Hitting the nozzles or wiping
them with a rag may cause the hole to clog. Also, injector wiring use high voltage, so make sure to remove the bat- them with a rag may cause the hole to clog. Also, injector wiring use high voltage, so make sure to remove the bat-
tery terminals before beginning work. tery terminals before beginning work.
High-pressure lines, seals, and packing that have been removed cannot be reused, so always replace them with High-pressure lines, seals, and packing that have been removed cannot be reused, so always replace them with
new parts. new parts.
[1] Use a wrench (17 mm) to remove the bolt (1), and [1] Use a wrench (17 mm) to remove the bolt (1), and
then remove the battery cable (2) on the negative then remove the battery cable (2) on the negative
side. 2 side. 2
• When removing the terminal and harness, secure 1 • When removing the terminal and harness, secure 1
them so that they do not interfere with the frame. them so that they do not interfere with the frame.
Also, cover with a rubber cap to protect against Also, cover with a rubber cap to protect against
sparks. sparks.

NF11002-092 NF11002-092

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3005-4 3005-4
[2] Use a wrench (12 mm) to remove the bolt (3), and [2] Use a wrench (12 mm) to remove the bolt (3), and
then remove the oil gauge line (4). 3 then remove the oil gauge line (4). 3
• Use caps and plugs to cover the line to prevent any • Use caps and plugs to cover the line to prevent any
entry of water, dust or dirt. entry of water, dust or dirt.
• Clean the line by spraying with a parts cleaner to • Clean the line by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumulat- 4 prevent scratches and prevent dirt from accumulat- 4
ing on the connectors. ing on the connectors.

3 RF11001-116 3 RF11001-116

[3] Use pliers to loosen the hose band, and then [3] Use pliers to loosen the hose band, and then
remove the blow-by hose (5). remove the blow-by hose (5).
• Use caps and plugs to cover the hose and line to • Use caps and plugs to cover the hose and line to
prevent any entry of water, dust or dirt. prevent any entry of water, dust or dirt.
5 5

RF11001-063 RF11001-063

[4] Use a wrench (12 mm) to remove the bolt (6) on the [4] Use a wrench (12 mm) to remove the bolt (6) on the
hose clamp (7). 6 hose clamp (7). 6

7 7

RF11001-064 RF11001-064

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3005-5 3005-5
[5] Use a wrench (12 mm) to remove the 9 bolts (8) on [5] Use a wrench (12 mm) to remove the 9 bolts (8) on
the cylinder head cover (10) and the 2 nuts (9), and 9 the cylinder head cover (10) and the 2 nuts (9), and 9
then remove the cylinder head cover. 8 then remove the cylinder head cover. 8
8 8
8 8

9 9

10 10

RF11001-065 RF11001-065

[6] Remove the connector (11). [6] Remove the connector (11).

11 11

RF11001-066 RF11001-066

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3005-6 3005-6
[7] Use a wrench (7 mm) to remove the 2 nuts (13) at [7] Use a wrench (7 mm) to remove the 2 nuts (13) at
each of the 4 injector terminal locations. 12 each of the 4 injector terminal locations. 12
[8] Use a wrench (14 mm) to loosen the 3 bolts (12), [8] Use a wrench (14 mm) to loosen the 3 bolts (12),
and then remove the harness bracket (14). and then remove the harness bracket (14).
13 13
• When removing the nuts, loosen them equally a little • When removing the nuts, loosen them equally a little
bit a time to simultaneously remove them. bit a time to simultaneously remove them.

14 14

RF11001-067 RF11001-067

[9] Use wrenches (12 mm, 17 mm) to remove the 5 [9] Use wrenches (12 mm, 17 mm) to remove the 5
bolts (15) and (16) and the 5 gaskets (17) and (18), bolts (15) and (16) and the 5 gaskets (17) and (18),
and then remove the nozzle leak-off pipe (19). 15 and then remove the nozzle leak-off pipe (19). 15
17 17

17 17
19 19

18 18

16 16

RF11001-068 RF11001-068

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3005-7 3005-7
[10]Use a wrench (10 mm) to remove the bolt (20) on [10]Use a wrench (10 mm) to remove the bolt (20) on
the line clamp (23). 21 23 the line clamp (23). 21 23
[11]Use a wrench (17 mm) to remove the sleeve nut [11]Use a wrench (17 mm) to remove the sleeve nut
(21) of the injector-side line. 20 (21) of the injector-side line. 20
[12]Use a wrench (19 mm) to remove the sleeve nuts [12]Use a wrench (19 mm) to remove the sleeve nuts
(22) of the common rail-side lines. (22) of the common rail-side lines.
• Use caps and plugs to cover the lines to prevent any • Use caps and plugs to cover the lines to prevent any
entry of water, dust or dirt. entry of water, dust or dirt.
• Clean the line by spraying with a parts cleaner to • Clean the line by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumulat- 22 prevent scratches and prevent dirt from accumulat- 22
ing on the connectors. ing on the connectors.

RF11001-069 RF11001-069

[13]Use a Torx wrench (T40) to remove the bolt (24) on [13]Use a Torx wrench (T40) to remove the bolt (24) on
the injector clamp (26). the injector clamp (26).
[14]Remove the injector (25). 25 24 [14]Remove the injector (25). 25 24

26 26

RF11001-117 RF11001-117

[15]Use the injector remover (28) when it is difficult to [15]Use the injector remover (28) when it is difficult to
remove the injector (29). remove the injector (29).
Install the injector remover on the injector line con- Install the injector remover on the injector line con-
nection section. Also connect the sliding hammer 27 nection section. Also connect the sliding hammer 27
(27) and then remove the injector. (27) and then remove the injector.
• Sliding hammer • Sliding hammer
Part No.: 380002602 28 Part No.: 380002602 28
• Injector remover • Injector remover
Part No.: 380002601 Part No.: 380002601

29 29

RF11001-104 RF11001-104

Lep SM130B3005-0EN Issued 03-08 Lep SM130B3005-0EN Issued 03-08


3005-8 3005-8
2 Installation of injector 2 Installation of injector
[1] Record the "QR code" (2) that appears on the top of [1] Record the "QR code" (2) that appears on the top of
the QR plate (1) of the replacement injector (3). 2 the QR plate (1) of the replacement injector (3). 2
The "QR code" is different for each injector, so The "QR code" is different for each injector, so
1 1
match the cylinder to be installed with the injector match the cylinder to be installed with the injector
and record the code. and record the code.
5564 7D9A 5564 7D9A
9EAA 8E8F 9EAA 8E8F
A090 8300 A090 8300
0000 BD 0000 BD

3 3

RF11001-105 RF11001-105

[2] Always replace the gasket (5) and O-ring (7). [2] Always replace the gasket (5) and O-ring (7).
Apply Molybdenum to the threaded section of the Apply Molybdenum to the threaded section of the
bolt (4) on the injector clamp (6) and seating sur- 4 bolt (4) on the injector clamp (6) and seating sur- 4
face. 3 face. 3
Install the injector (3) on the cylinder head. As 6 Install the injector (3) on the cylinder head. As 6
shown in the diagram, insert the injector by pressing shown in the diagram, insert the injector by pressing
it in with the clamp. Temporarily tighten the bolt on it in with the clamp. Temporarily tighten the bolt on
the injector clamp. the injector clamp.

7 7
5 5

RF11001-118 RF11001-118

Lep SM130B3005-0EN Issued 03-08 Lep SM130B3005-0EN Issued 03-08


3005-9 3005-9
[3] Apply a small amount of engine oil to the outside [3] Apply a small amount of engine oil to the outside
surface of the injector-side sleeve nut (10). 9 11 surface of the injector-side sleeve nut (10). 9 11
Install the line. Install the line.
Carefully tighten each of the sleeve nuts (9) and 8 Carefully tighten each of the sleeve nuts (9) and 8
(10) until the line is touching the common rail and (10) until the line is touching the common rail and
injector. injector.
Tighten the bolt (8) on the line clamp (11) to the Tighten the bolt (8) on the line clamp (11) to the
specified torque. specified torque.
Tightening torque: 6 Nm. Tightening torque: 6 Nm.

10 10

RF11001-140 RF11001-140

Fully tighten the bolt (4) on the injector clamp to the Fully tighten the bolt (4) on the injector clamp to the
specified torque. 4 specified torque. 4
Tightening torque: 30 Nm Tightening torque: 30 Nm
Tighten the line sleeve nuts to the specified torque. Tighten the line sleeve nuts to the specified torque.
Tightening torque: 44 Nm 9 Tightening torque: 44 Nm 9

10 10

RF11001-107 RF11001-107

[4] Install the nozzle leak-off pipe (16) with the bolts [4] Install the nozzle leak-off pipe (16) with the bolts
(12) and (13). (12) and (13).
Replace the gaskets (14) and (15). 12 Replace the gaskets (14) and (15). 12
14 14
Tighten each of the lines to the specified torque. Tighten each of the lines to the specified torque.
Tightening torque: 12 Nm Tightening torque: 12 Nm

14 14
16 16

15 15

13 13

RF11001-119 RF11001-119

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3005-10 3005-10
[5] Secure the harness bracket (19) with the bolts (17). [5] Secure the harness bracket (19) with the bolts (17).
Secure the bolts in sequence from the inside to the 17 Secure the bolts in sequence from the inside to the 17
outside. outside.
Tightening torque: 48 Nm Tightening torque: 48 Nm
[6] Install the injector terminal nuts (18) on each injec- 18 [6] Install the injector terminal nuts (18) on each injec- 18
tor. tor.
Tighten to the specified torque. Tighten to the specified torque.
Tightening torque: 2 Nm Tightening torque: 2 Nm
Be careful not to tighten the nuts too much. Be careful not to tighten the nuts too much.
Tightening all at once with a ratchet wrench, etc. Tightening all at once with a ratchet wrench, etc.
may cause damage to the terminal stud. 19 may cause damage to the terminal stud. 19

RF11001-141 RF11001-141

[7] Connect the injector harness connector (20). [7] Connect the injector harness connector (20).

20 20

RF11001-142 RF11001-142

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3005-11 3005-11
[8] Install the head gasket (24) on the cylinder head [8] Install the head gasket (24) on the cylinder head
cover (23) and tighten with each of the bolts (21) cover (23) and tighten with each of the bolts (21)
and nuts (22). 22 and nuts (22). 22
21 21
Tighten in the order shown in the diagram. Tighten in the order shown in the diagram.
Specified torque: 18 Nm 21 Specified torque: 18 Nm 21
21 21

22 22
24 24

1 3 7 1 3 7
5 23 5 23

9 9

8 8
6 2 4 6 2 4

RF11001-108 RF11001-108

RF11001-143 RF11001-143

[9] Install the hose clamp (26) with the bolt (25). [9] Install the hose clamp (26) with the bolt (25).
25 25

26 26

RF11001-144 RF11001-144

[10]Install the blow-by hose (27). [10]Install the blow-by hose (27).

27 27

RF11001-145 RF11001-145

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3005-12 3005-12
[11]Install the oil gauge line (29) with the bolts (28). [11]Install the oil gauge line (29) with the bolts (28).
• Be careful not to allow entry of any water, dust or 28 • Be careful not to allow entry of any water, dust or 28
dirt. dirt.
• Clean the line by spraying with a parts cleaner to • Clean the line by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumulat- prevent scratches and prevent dirt from accumulat-
ing on the connectors. 29 ing on the connectors. 29

28 RF11001-146 28 RF11001-146

[12]Install the negative-side battery cable (31) terminal. [12]Install the negative-side battery cable (31) terminal.
Be careful of shorts with the terminal and harness. Be careful of shorts with the terminal and harness.
31 31
30 30

NF11002-093 NF11002-093

[13]When replacing an injector (3) with a new one, [13]When replacing an injector (3) with a new one,
make sure to enter the QR code of the replaced make sure to enter the QR code of the replaced
injector into the ECM. injector into the ECM.
[14]See the Section 4001 for this procedure. [14]See the Section 4001 for this procedure.

Lep SM130B3005-0EN Issued 03-08 Lep SM130B3005-0EN Issued 03-08


4001

4001
Section Section
4001 4001

ELECTRICAL AND ENGINE FUNCTIONS, ELECTRICAL AND ENGINE FUNCTIONS,


& &
SERVICE SUPPORT SERVICE SUPPORT

Copyright © 2007 CNH France S.A. Copyright © 2007 CNH France S.A.
Printed in France Printed in France
CNH Lep SC130B4001-0EN November 2007 CNH Lep SC130B4001-0EN November 2007
4001-2 4001-2
TABLE OF CONTENTS TABLE OF CONTENTS

ELECTRIC CIRCUITS OPERATION EXPLANATION .................................................................................................. 5 ELECTRIC CIRCUITS OPERATION EXPLANATION .................................................................................................. 5
Explanation of Electrical Functions ..................................................................................................................... 5 Explanation of Electrical Functions ..................................................................................................................... 5
Engine Speed Control ............................................................................................................................................ 7 Engine Speed Control ............................................................................................................................................ 7
Throttle Control .................................................................................................................................................... 7 Throttle Control .................................................................................................................................................... 7
Idling Control (auto / one-touch) ......................................................................................................................... 11 Idling Control (auto / one-touch) ......................................................................................................................... 11
Idling Start .......................................................................................................................................................... 12 Idling Start .......................................................................................................................................................... 12
Idle Up ................................................................................................................................................................ 13 Idle Up ................................................................................................................................................................ 13
Auto Warm Up .................................................................................................................................................... 13 Auto Warm Up .................................................................................................................................................... 13
Engine Start / Stop Control ................................................................................................................................. 15 Engine Start / Stop Control ................................................................................................................................. 15
Engine Start / Stop Judgment ............................................................................................................................ 15 Engine Start / Stop Judgment ............................................................................................................................ 15
Power-Cut Delay ................................................................................................................................................ 16 Power-Cut Delay ................................................................................................................................................ 16
Engine Emergency Stop .................................................................................................................................... 17 Engine Emergency Stop .................................................................................................................................... 17
Neutral Start ....................................................................................................................................................... 18 Neutral Start ....................................................................................................................................................... 18
Pump Control ....................................................................................................................................................... 19 Pump Control ....................................................................................................................................................... 19
Work Mode Control ............................................................................................................................................ 19 Work Mode Control ............................................................................................................................................ 19
Pump Horsepower Boost Control ....................................................................................................................... 20 Pump Horsepower Boost Control ....................................................................................................................... 20
Pump Horsepower Cut Control .......................................................................................................................... 21 Pump Horsepower Cut Control .......................................................................................................................... 21
Swing ..................................................................................................................................................................... 22 Swing ..................................................................................................................................................................... 22
Swing Brake ....................................................................................................................................................... 22 Swing Brake ....................................................................................................................................................... 22
Free Swing (North America Only) ...................................................................................................................... 23 Free Swing (North America Only) ...................................................................................................................... 23
Swing Lock (for maintenance) ............................................................................................................................ 24 Swing Lock (for maintenance) ............................................................................................................................ 24
Swing Relief Cut ................................................................................................................................................. 25 Swing Relief Cut ................................................................................................................................................. 25
Travel ..................................................................................................................................................................... 27 Travel ..................................................................................................................................................................... 27
Travel Speed Switchover ................................................................................................................................... 27 Travel Speed Switchover ................................................................................................................................... 27
Travel Alarm (North America only) ..................................................................................................................... 28 Travel Alarm (North America only) ..................................................................................................................... 28
Valve Control ........................................................................................................................................................ 30 Valve Control ........................................................................................................................................................ 30
Lever Lock .......................................................................................................................................................... 30 Lever Lock .......................................................................................................................................................... 30
Solenoid Sticking Prevention ............................................................................................................................. 31 Solenoid Sticking Prevention ............................................................................................................................. 31
Pressure Boost Control ...................................................................................................................................... 32 Pressure Boost Control ...................................................................................................................................... 32
Monitor Control .................................................................................................................................................... 34 Monitor Control .................................................................................................................................................... 34
Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge) .................................................... 34 Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge) .................................................... 34
Accessories .......................................................................................................................................................... 40 Accessories .......................................................................................................................................................... 40
Horn ................................................................................................................................................................... 40 Horn ................................................................................................................................................................... 40
Working Light ..................................................................................................................................................... 41 Working Light ..................................................................................................................................................... 41
Wiper & Washer ................................................................................................................................................. 42 Wiper & Washer ................................................................................................................................................. 42
Room Lamp ........................................................................................................................................................ 44 Room Lamp ........................................................................................................................................................ 44
Radio Mute ......................................................................................................................................................... 46 Radio Mute ......................................................................................................................................................... 46
Others .................................................................................................................................................................... 47 Others .................................................................................................................................................................... 47
Anti-Theft ............................................................................................................................................................ 47 Anti-Theft ............................................................................................................................................................ 47
Battery Save Function ........................................................................................................................................ 48 Battery Save Function ........................................................................................................................................ 48
Alternator Power Generation Detection ............................................................................................................. 49 Alternator Power Generation Detection ............................................................................................................. 49
Overload Alarm (Europe only) ............................................................................................................................ 50 Overload Alarm (Europe only) ............................................................................................................................ 50
Options .................................................................................................................................................................. 52 Options .................................................................................................................................................................. 52
Option Line Control ............................................................................................................................................ 52 Option Line Control ............................................................................................................................................ 52
Option Line Control ............................................................................................................................................ 55 Option Line Control ............................................................................................................................................ 55
Feed Pump Automatic Stop ............................................................................................................................... 57 Feed Pump Automatic Stop ............................................................................................................................... 57
Return Filter Clogging Detected ......................................................................................................................... 60 Return Filter Clogging Detected ......................................................................................................................... 60
Beacon (Europe Only) ........................................................................................................................................ 61 Beacon (Europe Only) ........................................................................................................................................ 61
ENGINE SUMMARY .................................................................................................................................................... 63 ENGINE SUMMARY .................................................................................................................................................... 63
Engine System Diagram .................................................................................................................................... 63 Engine System Diagram .................................................................................................................................... 63
Fuel System Diagram ......................................................................................................................................... 64 Fuel System Diagram ......................................................................................................................................... 64
Detailed Part ...................................................................................................................................................... 65 Detailed Part ...................................................................................................................................................... 65
Engine Control Summary ................................................................................................................................... 72 Engine Control Summary ................................................................................................................................... 72

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4001-3 4001-3
EXPLANATION OF ENGINE FUNCTION ....................................................................................................................73 EXPLANATION OF ENGINE FUNCTION ....................................................................................................................73
Engine Function Explanation table .....................................................................................................................73 Engine Function Explanation table .....................................................................................................................73
EGR (Exhaust Gas Recirculation) ......................................................................................................................74 EGR (Exhaust Gas Recirculation) ......................................................................................................................74
Relationship between ECM and sensor actuators ..............................................................................................75 Relationship between ECM and sensor actuators ..............................................................................................75
Cautions for Maintenance ...................................................................................................................................76 Cautions for Maintenance ...................................................................................................................................76
Explanation of Engine Control ............................................................................................................................78 Explanation of Engine Control ............................................................................................................................78
Engine Start/Stop Judgment ...............................................................................................................................82 Engine Start/Stop Judgment ...............................................................................................................................82
SERVICE SUPPORT ....................................................................................................................................................83 SERVICE SUPPORT ....................................................................................................................................................83
Screen Operations ................................................................................................................................................83 Screen Operations ................................................................................................................................................83
Screen Display List ...............................................................................................................................................85 Screen Display List ...............................................................................................................................................85
CHK (status display) Screen List ........................................................................................................................85 CHK (status display) Screen List ........................................................................................................................85
MAIN ...............................................................................................................................................................85 MAIN ...............................................................................................................................................................85
MNT ................................................................................................................................................................88 MNT ................................................................................................................................................................88
H / W-A ...........................................................................................................................................................90 H / W-A ...........................................................................................................................................................90
H / W-B ...........................................................................................................................................................93 H / W-B ...........................................................................................................................................................93
H / W-M ...........................................................................................................................................................96 H / W-M ...........................................................................................................................................................96
DIAG (trouble diagnosis) Screen ........................................................................................................................97 DIAG (trouble diagnosis) Screen ........................................................................................................................97
Screen ............................................................................................................................................................97 Screen ............................................................................................................................................................97
Operation ........................................................................................................................................................98 Operation ........................................................................................................................................................98
Reset ..............................................................................................................................................................98 Reset ..............................................................................................................................................................98
HR (usage log) Screen List .................................................................................................................................99 HR (usage log) Screen List .................................................................................................................................99
MAIN ...............................................................................................................................................................99 MAIN ...............................................................................................................................................................99
ENG ..............................................................................................................................................................101 ENG ..............................................................................................................................................................101
CFG (setting change) Screen ...........................................................................................................................104 CFG (setting change) Screen ...........................................................................................................................104
Operation ......................................................................................................................................................104 Operation ......................................................................................................................................................104
Screen ..........................................................................................................................................................105 Screen ..........................................................................................................................................................105
CAL (troubleshooting support) Screen ..............................................................................................................107 CAL (troubleshooting support) Screen ..............................................................................................................107
Operation ......................................................................................................................................................107 Operation ......................................................................................................................................................107
Screen ..........................................................................................................................................................107 Screen ..........................................................................................................................................................107
Check the Monitor Switch (Self-diagnosis function) ..........................................................................................110 Check the Monitor Switch (Self-diagnosis function) ..........................................................................................110
Screen ..........................................................................................................................................................110 Screen ..........................................................................................................................................................110
Configuration ................................................................................................................................................110 Configuration ................................................................................................................................................110
Differences from CHK screen [CHK | H/W-M | 1] .........................................................................................111 Differences from CHK screen [CHK | H/W-M | 1] .........................................................................................111
Option Flow Setting ...........................................................................................................................................112 Option Flow Setting ...........................................................................................................................................112
Screen ..........................................................................................................................................................112 Screen ..........................................................................................................................................................112
Flow setting ...................................................................................................................................................112 Flow setting ...................................................................................................................................................112
Anti-theft Setting ...............................................................................................................................................114 Anti-theft Setting ...............................................................................................................................................114
Anti-theft setting and password registration ..................................................................................................114 Anti-theft setting and password registration ..................................................................................................114
Anti-theft function operation ..........................................................................................................................115 Anti-theft function operation ..........................................................................................................................115
Model Setting ....................................................................................................................................................116 Model Setting ....................................................................................................................................................116
Engine Screen Information ...............................................................................................................................118 Engine Screen Information ...............................................................................................................................118
Purpose ........................................................................................................................................................118 Purpose ........................................................................................................................................................118
How to go to this screen ...............................................................................................................................118 How to go to this screen ...............................................................................................................................118
Engine start restriction ..................................................................................................................................118 Engine start restriction ..................................................................................................................................118
Screen ..........................................................................................................................................................118 Screen ..........................................................................................................................................................118
Operating method .........................................................................................................................................118 Operating method .........................................................................................................................................118
Monitor operation method .............................................................................................................................119 Monitor operation method .............................................................................................................................119
Engine Information (Q resistance, QR code, engine serial number) Copying Method .................................120 Engine Information (Q resistance, QR code, engine serial number) Copying Method .................................120
Rewriting Injector QR Codes ........................................................................................................................121 Rewriting Injector QR Codes ........................................................................................................................121
When Replacing Computer A at the Same Time ..........................................................................................123 When Replacing Computer A at the Same Time ..........................................................................................123
Engine Information Obtained Timing ............................................................................................................123 Engine Information Obtained Timing ............................................................................................................123
Redoing Engine Information Obtained ..........................................................................................................123 Redoing Engine Information Obtained ..........................................................................................................123
Trouble Display .............................................................................................................................................123 Trouble Display .............................................................................................................................................123
Screen Display Details .......................................................................................................................................124 Screen Display Details .......................................................................................................................................124
Message Display List ........................................................................................................................................124 Message Display List ........................................................................................................................................124
Trouble Display ...................................................................................................................................................126 Trouble Display ...................................................................................................................................................126
Diagnostic Trouble Code Display ......................................................................................................................126 Diagnostic Trouble Code Display ......................................................................................................................126
Main Unit Diagnostic Trouble Code List ............................................................................................................127 Main Unit Diagnostic Trouble Code List ............................................................................................................127

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Diagnostic Trouble Code (Monitor Display) ..................................................................................................... 131 Diagnostic Trouble Code (Monitor Display) ..................................................................................................... 131
Sensor Trouble Operation Table ...................................................................................................................... 137 Sensor Trouble Operation Table ...................................................................................................................... 137
EPF (engine protection feature) ....................................................................................................................... 139 EPF (engine protection feature) ....................................................................................................................... 139

CNH-EST DIAGNOSTIC TOOL CNH-EST DIAGNOSTIC TOOL

The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the operating The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the operating
parameters of electronic control components (control units, sensors etc.). It is also capable of reading fault codes. parameters of electronic control components (control units, sensors etc.). It is also capable of reading fault codes.
To use this tool, please refer to the book provided during the CXB series training sessions. To use this tool, please refer to the book provided during the CXB series training sessions.

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4001-5 4001-5
ELECTRIC CIRCUITS OPERATION EXPLANATION ELECTRIC CIRCUITS OPERATION EXPLANATION

Explanation of Electrical Functions Explanation of Electrical Functions

No. Item Control Contents No. Item Control Contents


1 Throttle Control The engine speed, work mode, and boosted pressure state 1 Throttle Control The engine speed, work mode, and boosted pressure state
are switched by the throttle volume. are switched by the throttle volume.
2 Idling Control With auto / one-touch switchover function 2 Idling Control With auto / one-touch switchover function
Engine Engine
3 Idling Start Runs the engine at low idle speed when it starts up. 3 Idling Start Runs the engine at low idle speed when it starts up.
1 Speed 1 Speed
Control 4 Idle Up In order to prevent the engine from stalling, during operation, Control 4 Idle Up In order to prevent the engine from stalling, during operation,
raises the low idle speed to the auto idle speed. raises the low idle speed to the auto idle speed.
5 Auto Warm Up If the coolant temperature is low, warm-up operation is 5 Auto Warm Up If the coolant temperature is low, warm-up operation is
executed automatically when the engine starts executed automatically when the engine starts
1 Engine Start / Stop Judgment based on engine speed from ECM 1 Engine Start / Stop Judgment based on engine speed from ECM
Judgment Judgment
Engine Start 2 Power-Cut Delay When key ON OFF, 4-second delay; when engine running Engine Start 2 Power-Cut Delay When key ON OFF, 4-second delay; when engine running
2 / Stop OFF, 7-second delay 2 / Stop OFF, 7-second delay
Control 3 Engine Emergency When the emergency stop switch is pressed, the ECM Control 3 Engine Emergency When the emergency stop switch is pressed, the ECM
Stop recognizes this and stops the engine. Stop recognizes this and stops the engine.
4 Neutral Start Control Engine start load (cell not turning) when lever locked 4 Neutral Start Control Engine start load (cell not turning) when lever locked
1 Work Mode Control Linked with the throttle, the SP / H / A mode is switched over 1 Work Mode Control Linked with the throttle, the SP / H / A mode is switched over
and the pump horsepower is controlled. and the pump horsepower is controlled.
2 Pump Horsepower The pump horsepower milli-amp is raised when there is a high 2 Pump Horsepower The pump horsepower milli-amp is raised when there is a high
Pump Pump
3 Boost Control load or sharp load. 3 Boost Control load or sharp load.
Control Control
3 Pump Horsepower Cut The pump horsepower milli-amp is reduced by the transient 3 Pump Horsepower Cut The pump horsepower milli-amp is reduced by the transient
Control load control, engine stall prevention control, and PID control Control load control, engine stall prevention control, and PID control
conditions. conditions.
1 Swing Brake When the upper and swing are not operated, the swing brake 1 Swing Brake When the upper and swing are not operated, the swing brake
is operated automatically and during travelling too is operated automatically and during travelling too
2 Swing Free Swing Swing option for North America 2 Swing Free Swing Swing option for North America
(option) (option)
3 Swing Lock There is a swing lock function (for servicing) with monitor 3 Swing Lock There is a swing lock function (for servicing) with monitor
4 Swing 4 Swing
operations. operations.
4 Swing Relief Cut When a swing starts, the flow is reduced with the front side 4 Swing Relief Cut When a swing starts, the flow is reduced with the front side
proportional valve and the excess oil is eliminated. proportional valve and the excess oil is eliminated.
5 Swing Speed Limit The front side flow is controlled to suppress the speed rise 5 Swing Speed Limit The front side flow is controlled to suppress the speed rise
due to increased pump flow due to increased pump flow
1 Travel Speed Travel speed low-speed / high-speed switchover 1 Travel Speed Travel speed low-speed / high-speed switchover
5 Travel Switchover 5 Travel Switchover
2 Travel Alarm Buzzer sounded (for 10 seconds) during travel 2 Travel Alarm Buzzer sounded (for 10 seconds) during travel
1 Lever Lock Operation is not possible unless the gate lever is raised. 1 Lever Lock Operation is not possible unless the gate lever is raised.
2 Solenoid Sticking When key ON, solenoid switched ON / OFF for 0.25 second. 2 Solenoid Sticking When key ON, solenoid switched ON / OFF for 0.25 second.
Valve Prevention Valve Prevention
6 6
Control 3 Pressure Boost Control The computer automatically raises the pressure from 34.3 Control 3 Pressure Boost Control The computer automatically raises the pressure from 34.3
MPa (433 bar / 4975 psi) => 36.8 MPa (368 bar / 5338 psi) MPa (433 bar / 4975 psi) => 36.8 MPa (368 bar / 5338 psi)
when necessary. when necessary.
1 Monitor Function Output port control method change, lift crane and option 1 Monitor Function Output port control method change, lift crane and option
Monitor screen added to display screens, etc. Monitor screen added to display screens, etc.
7 7
Control 2 Monitor Bar Graph Bar graph display of coolant temperature, oil temperature, and Control 2 Monitor Bar Graph Bar graph display of coolant temperature, oil temperature, and
fuel level on monitor fuel level on monitor

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No. Item Control Contents No. Item Control Contents


1 Horn Switching between one or two horns with horn volume select 1 Horn Switching between one or two horns with horn volume select
switch switch
2 Working Light Right housing and boom light illumination (option setting for 2 Working Light Right housing and boom light illumination (option setting for
two lights at top of cab) two lights at top of cab)
8 Accessories 3 Wiper & Washer Wiper with rise-up used (intermittent, continuous, washer) 8 Accessories 3 Wiper & Washer Wiper with rise-up used (intermittent, continuous, washer)
4 Room Lamp The room lamp lights up when the door is opened and lights 4 Room Lamp The room lamp lights up when the door is opened and lights
up for exactly 30 seconds from when the door is opened with up for exactly 30 seconds from when the door is opened with
the key OFF. the key OFF.
5 Radio Mute Mute switch setting on the knob 5 Radio Mute Mute switch setting on the knob
1 Anti-Theft Anti-theft set with password input to monitor 1 Anti-Theft Anti-theft set with password input to monitor
2 Battery Save Function When the key is ON, no output to travel switchover, boost, 2 Battery Save Function When the key is ON, no output to travel switchover, boost,
power save, bucket lock, option switchover and free swing power save, bucket lock, option switchover and free swing
9 Others solenoid valve. 9 Others solenoid valve.
3 Alternator Power Alternator L terminal voltage judged with 10 V comparator 3 Alternator Power Alternator L terminal voltage judged with 10 V comparator
Generation Detection Generation Detection
4 Overload Alarm Only mounted on machines for Europe 4 Overload Alarm Only mounted on machines for Europe
1 Option Line Control Switchover crusher / breaker with just rocker switch in cab 1 Option Line Control Switchover crusher / breaker with just rocker switch in cab
2 Option Line Control There are five flow settings each for the breaker and crusher, 2 Option Line Control There are five flow settings each for the breaker and crusher,
for a total of 10 settings. for a total of 10 settings.
3 DC-DC Converter Convert 24 V into 12 V 3 DC-DC Converter Convert 24 V into 12 V
10 Options 4 Feed Pump Automatic Feed pump automatic stop. Full tank detected by fuel level 10 Options 4 Feed Pump Automatic Feed pump automatic stop. Full tank detected by fuel level
Stop sensor and the pump stopped automatically Stop sensor and the pump stopped automatically
5 Return Filter Clogging Alarm issued when return filter clogged (only for breaker 5 Return Filter Clogging Alarm issued when return filter clogged (only for breaker
Detected specifications) Detected specifications)
6 Beacon Control Standard for Europe. 6 Beacon Control Standard for Europe.
(rotating light) (rotating light)
11 Engine Common rail control 11 Engine Common rail control

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Engine Speed Control Engine Speed Control
1. Throttle Control 1. Throttle Control
1) Throttle display 1) Throttle display
a) Configuration a) Configuration

Throttle display data Throttle display data

Throttle display Throttle display

Target engine speed Target engine speed

1 Monitor 3 Engine 1 Monitor 3 Engine


2 Computer A 4 Throttle volume 2 Computer A 4 Throttle volume

b) Summary b) Summary
The throttle volume voltage signal is first input to Computer A. Computer A converts the voltage signal to a The throttle volume voltage signal is first input to Computer A. Computer A converts the voltage signal to a
target speed and sends it to the ECM with CAN communications. target speed and sends it to the ECM with CAN communications.
At the same time, Computer A sends the throttle display data to the monitor. At the same time, Computer A sends the throttle display data to the monitor.
2) Throttle volume position detection 2) Throttle volume position detection
a) Configuration a) Configuration

1 Throttle volume 1 Throttle volume


2 Computer A 2 Computer A
3 Potentiometer 3 Potentiometer

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b) Structure b) Structure
The detent and notches provide a click feel (15 notches; Notch 1 is the "SP mode" position). The detent and notches provide a click feel (15 notches; Notch 1 is the "SP mode" position).

Hysteresis about 2.5° Hysteresis about 2.5°

(Right turn) (Right turn)


When the detent When the detent
Small notch: 4 to 15 Large notch: 1 to 3 reaches the N- position, Small notch: 4 to 15 Large notch: 1 to 3 reaches the N- position,
it is judged to beat it is judged to beat
Notch N. Notch N.
(Left turn) (Left turn)
When the detent When the detent
reaches the N+ position, reaches the N+ position,
it is judged to be at it is judged to be at
Notch N. Notch N.
Left turn Right turn Notch number (1 to 15) Left turn Right turn Notch number (1 to 15)

Notch N Notch N
Detent Detent
detent position detection: detent position detection:
Hysteresis is used to Hysteresis is used to
absorb error. absorb error.
c) Characteristic c) Characteristic

Target engine speed Hysteresis Target engine speed Hysteresis

Detent position (notch number) Detent position (notch number)

(AUTO) (AUTO)

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d) Potentiometer characteristic d) Potentiometer characteristic
Voltage (V) Voltage (V)

Angle (deg) Angle (deg)


Throttle operation range Throttle operation range

Trouble Normal Trouble Trouble Normal Trouble

Potentiometer operation range Potentiometer operation range

e) Throttle volume degree of opening calculation e) Throttle volume degree of opening calculation
The throttle volume degree of opening (%) that can be checked on the CHK screen is calculated with the The throttle volume degree of opening (%) that can be checked on the CHK screen is calculated with the
standard below. standard below.
100% => When the detent is in the 1+ position 100% => When the detent is in the 1+ position
0% => When the detent is in the 15- position 0% => When the detent is in the 15- position
Therefore, even if the detent is in the 1 position (SP), this does not necessarily mean that the degree of Therefore, even if the detent is in the 1 position (SP), this does not necessarily mean that the degree of
opening is 100%. opening is 100%.
In the same way, even if the detent is in the 0 position, the degree of opening is not necessarily 0%. In the same way, even if the detent is in the 0 position, the degree of opening is not necessarily 0%.

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f) Table f) Table
For the angle, voltage, and degree of opening for each detent position, see the following table. For the angle, voltage, and degree of opening for each detent position, see the following table.

Degree of Degree of
Detent Angle [degree] Voltage [V] Detent Angle [degree] Voltage [V]
opening [%] opening [%]
1+ 131.2 4.86 100.0 1+ 131.2 4.86 100.0
1 128.7 4.77 98.0 1 128.7 4.77 98.0
1- 126.2 4.67 96.1 1- 126.2 4.67 96.1
2+ 109.6 4.06 83.0 2+ 109.6 4.06 83.0
2 107.1 3.97 81.1 2 107.1 3.97 81.1
2- 104.6 3.87 79.1 2- 104.6 3.87 79.1
3+ 95.2 3.53 71.7 3+ 95.2 3.53 71.7
3 92.7 3.43 69.8 3 92.7 3.43 69.8
3- 90.2 3.34 67.8 3- 90.2 3.34 67.8
4+ 88.0 3.26 66.1 4+ 88.0 3.26 66.1
4 85.5 3.17 64.1 4 85.5 3.17 64.1
4- 83.0 3.07 62.2 4- 83.0 3.07 62.2
5+ 80.8 2.99 60.4 5+ 80.8 2.99 60.4
5 78.3 2.90 58.5 5 78.3 2.90 58.5
5- 75.8 2.81 56.5 5- 75.8 2.81 56.5
6+ 73.6 2.73 54.8 6+ 73.6 2.73 54.8
6 71.1 2.63 52.8 6 71.1 2.63 52.8
6- 68.6 2.54 50.9 6- 68.6 2.54 50.9
7+ 66.4 2.46 49.1 7+ 66.4 2.46 49.1
7 63.9 2.37 47.2 7 63.9 2.37 47.2
7- 61.4 2.27 45.2 7- 61.4 2.27 45.2
8+ 59.2 2.19 43.5 8+ 59.2 2.19 43.5
8 56.7 2.10 41.5 8 56.7 2.10 41.5
8- 54.2 2.01 39.6 8- 54.2 2.01 39.6
9+ 52.0 1.93 37.8 9+ 52.0 1.93 37.8
9 49.5 1.83 35.9 9 49.5 1.83 35.9
9- 47.0 1.74 33.9 9- 47.0 1.74 33.9
10+ 44.8 1.66 32.2 10+ 44.8 1.66 32.2
10 42.3 1.57 30.2 10 42.3 1.57 30.2
10- 39.8 1.47 28.3 10- 39.8 1.47 28.3
11+ 37.6 1.39 26.5 11+ 37.6 1.39 26.5
11 35.1 1.30 24.6 11 35.1 1.30 24.6
11- 32.6 1.21 22.6 11- 32.6 1.21 22.6
12+ 30.4 1.13 20.9 12+ 30.4 1.13 20.9
12 27.9 1.03 18.9 12 27.9 1.03 18.9
12- 25.4 0.94 17.0 12- 25.4 0.94 17.0
13+ 23.2 0.86 15.2 13+ 23.2 0.86 15.2
13 20.7 0.77 13.3 13 20.7 0.77 13.3
13- 18.2 0.67 11.3 13- 18.2 0.67 11.3
14+ 16.0 0.59 9.6 14+ 16.0 0.59 9.6
14 13.5 0.50 7.6 14 13.5 0.50 7.6
14- 11.0 0.41 5.7 14- 11.0 0.41 5.7
15+ 8.8 0.33 3.9 15+ 8.8 0.33 3.9
15 6.3 0.23 2.0 15 6.3 0.23 2.0
15- 3.8 0.14 0.0 15- 3.8 0.14 0.0

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2. Idling Control (auto / one-touch) 2. Idling Control (auto / one-touch)

1 Monitor display 5 One-touch idle switch 9 Pressure sensor (upper) 1 Monitor display 5 One-touch idle switch 9 Pressure sensor (upper)
2 Computer A 6 Throttle volume 10 Pressure sensor (swing) 2 Computer A 6 Throttle volume 10 Pressure sensor (swing)
3 Engine 7 1st option pressure switch 11 Pressure sensor (travel) 3 Engine 7 1st option pressure switch 11 Pressure sensor (travel)
4 Coolant temperature sensor 8 2nd option pressure switch ECM Engine Control Module 4 Coolant temperature sensor 8 2nd option pressure switch ECM Engine Control Module

Operation explanation: Operation explanation:


a) Auto / one-touch switchover function a) Auto / one-touch switchover function
The operator can switch between one-touch and auto by pressing the auto idle switch on the monitor in the The operator can switch between one-touch and auto by pressing the auto idle switch on the monitor in the
figure below. figure below.
When auto idle is ON, the LED at the side of the switch lights up. When auto idle is ON, the LED at the side of the switch lights up.

b) Auto idle control (A) b) Auto idle control (A)


1. When auto idle is set, if the lever is left continuously unoperated for 5 seconds, the engine speed 1. When auto idle is set, if the lever is left continuously unoperated for 5 seconds, the engine speed
automatically becomes the auto idle speed (1200 min-1). automatically becomes the auto idle speed (1200 min-1).
This five-second setting for auto idle operation is the default setting value. This setting can be changed This five-second setting for auto idle operation is the default setting value. This setting can be changed
to from 1 to 30 seconds with service support operations. to from 1 to 30 seconds with service support operations.
2. When the lever is operated, the engine speed is automatically returned to the engine speed set for the 2. When the lever is operated, the engine speed is automatically returned to the engine speed set for the
throttle volume. throttle volume.
3. Even with auto idle set, it is possible to move to auto idle or return from auto idle by pressing the knob 3. Even with auto idle set, it is possible to move to auto idle or return from auto idle by pressing the knob
switch (one-touch idle switch) on the right operation lever. switch (one-touch idle switch) on the right operation lever.
c) One-touch idle control c) One-touch idle control
When auto idle is not set, regardless of lever operation, it is possible to move to auto idle or return from When auto idle is not set, regardless of lever operation, it is possible to move to auto idle or return from
auto idle by pressing the knob switch (one-touch idle switch) on the right operation lever. auto idle by pressing the knob switch (one-touch idle switch) on the right operation lever.
The idling speed for one-touch idle control is 1050 min-1. The idling speed for one-touch idle control is 1050 min-1.

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d) Idling speed d) Idling speed
1. Auto idling speed => 1200 min-1 1. Auto idling speed => 1200 min-1
2. One-touch idling speed => 1050 min-1. 2. One-touch idling speed => 1050 min-1.
3. Low idling speed => 1050 min-1. 3. Low idling speed => 1050 min-1.
The speeds above are the default values. They can be set to from 1000 to 1600 min -1 with service The speeds above are the default values. They can be set to from 1000 to 1600 min -1 with service
support operation (See Screen Operation in Service Support). However, the settings are based on the support operation (See Screen Operation in Service Support). However, the settings are based on the
following conditions. following conditions.
Low idle speed = One-touch idle speed ≤ Auto-idle speed Low idle speed = One-touch idle speed ≤ Auto-idle speed
(The one-touch idle speed and auto-idle speed settings can be changed). (The one-touch idle speed and auto-idle speed settings can be changed).

3. Idling Start 3. Idling Start


a) When the engine starts, the engine speed becomes the low idle speed regardless of the throttle position. a) When the engine starts, the engine speed becomes the low idle speed regardless of the throttle position.
b) When the low idle speed is changed, the engine speed is controlled at this new speed. b) When the low idle speed is changed, the engine speed is controlled at this new speed.
c) During an idling start, the idling icon (A) is displayed at the top left of the monitor. c) During an idling start, the idling icon (A) is displayed at the top left of the monitor.
No message is displayed No message is displayed
. .

d) An idling start is ended in the following cases and control becomes normal. d) An idling start is ended in the following cases and control becomes normal.
1. When the one-touch idle switch is pressed 1. When the one-touch idle switch is pressed
2. When the throttle volume is operated 2. When the throttle volume is operated
3. When the operation lever is operated (upper, travel, swing pressure sensor ON) 3. When the operation lever is operated (upper, travel, swing pressure sensor ON)
e) Back-up operation e) Back-up operation
1. Sensor trouble 1. Sensor trouble
If trouble occurs in a sensor (upper, travel, swing), the idling start is ended. If trouble occurs in a sensor (upper, travel, swing), the idling start is ended.
2. Throttle volume trouble 2. Throttle volume trouble
Even if the throttle volume is operated, the idling start is not ended. Also, even if the idling start is ended Even if the throttle volume is operated, the idling start is not ended. Also, even if the idling start is ended
with some other method, the throttle cannot be adjusted. with some other method, the throttle cannot be adjusted.
3. One-touch idle switch trouble 3. One-touch idle switch trouble
Even if the switch is pressed, the idling start is not ended. Even if the switch is pressed, the idling start is not ended.

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4. Idle Up 4. Idle Up
A function that when the engine speed is less than the idling speed, causes lever operation to automatically A function that when the engine speed is less than the idling speed, causes lever operation to automatically
raise the engine speed to the auto idling speed (Idle speed engine stall prevention function). raise the engine speed to the auto idling speed (Idle speed engine stall prevention function).
Operation conditions: Operation conditions:
a) Control only when the engine speed is lower than the auto idling speed a) Control only when the engine speed is lower than the auto idling speed
b) The idle up speed is the same as the auto idling speed (Factory setting 1200 min-1). b) The idle up speed is the same as the auto idling speed (Factory setting 1200 min-1).
c) This control does not operate when the idling speed is higher than the auto idling speed. Also, when auto idling c) This control does not operate when the idling speed is higher than the auto idling speed. Also, when auto idling
is operated, normally the auto idling function operates. is operated, normally the auto idling function operates.
d) Even with one-touch idling operating, this control operates to raise the idling speed. d) Even with one-touch idling operating, this control operates to raise the idling speed.
e) A lever is judged to have been operated when any pressure sensor (upper, travel, swing, arm-in) comes ON. e) A lever is judged to have been operated when any pressure sensor (upper, travel, swing, arm-in) comes ON.
f) If trouble occurs in any of the above pressure sensors, idle up control is not executed. f) If trouble occurs in any of the above pressure sensors, idle up control is not executed.
Auto idle (down) Auto idle (down)

Idle up Throttle volume operation Idle up Throttle volume operation

Idle up speed Idle up speed


(auto-idle speed) (auto-idle speed)

Engine speed 5 seconds Engine speed 5 seconds

Pressure sensor SIG Pressure sensor SIG


(operation lever) (operation lever)

5. Auto Warm Up 5. Auto Warm Up


If the coolant temperature is low when the engine starts up, warm-up operation is executed, automatically raising the If the coolant temperature is low when the engine starts up, warm-up operation is executed, automatically raising the
engine speed in steps. engine speed in steps.
a) Auto warm up is used if the coolant temperature is lower than 50 °C (122°F) when the engine starts. a) Auto warm up is used if the coolant temperature is lower than 50 °C (122°F) when the engine starts.
b) If the coolant temperature is 50 °C (122°F) or higher, auto warm up is not used and an "idling start" is executed. b) If the coolant temperature is 50 °C (122°F) or higher, auto warm up is not used and an "idling start" is executed.
c) Operation c) Operation
The engine speed is raised in steps from the low idle speed until 2000 rpm as below. The engine speed is raised in steps from the low idle speed until 2000 rpm as below.
When the low idle speed is changed, the engine speed starts from the newly set speed. When the low idle speed is changed, the engine speed starts from the newly set speed.
The warm up time is the same, 14 minutes. The warm up time is the same, 14 minutes.
When the coolant temperature reaches 50 °C (122°F), the engine speed falls immediately to low idle When the coolant temperature reaches 50 °C (122°F), the engine speed falls immediately to low idle
(Idling start). (Idling start).

Low idle Low idle

Low idle Low idle

5 minutes 3 minutes 3 minutes 3 minutes 5 minutes 3 minutes 3 minutes 3 minutes

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d) Monitor display d) Monitor display
During auto warm up, the “Auto warm up icon” (A) is displayed at the top left of the monitor. During auto warm up, the “Auto warm up icon” (A) is displayed at the top left of the monitor.

e) In the cases below, auto warm up is ended and operation shifts to "idling start". e) In the cases below, auto warm up is ended and operation shifts to "idling start".
1. When the coolant temperature reaches 50 °C (122°F) 1. When the coolant temperature reaches 50 °C (122°F)
2. When the one-touch idle switch is pressed 2. When the one-touch idle switch is pressed
3. When the entire auto warm up process ends (after 14 minutes) 3. When the entire auto warm up process ends (after 14 minutes)
f) In the cases below, auto warm up is ended and operation shifts to the engine speed for the throttle position. f) In the cases below, auto warm up is ended and operation shifts to the engine speed for the throttle position.
1. When the lever is operated (as detected by a pressure sensor) 1. When the lever is operated (as detected by a pressure sensor)
2. When the throttle volume is operated 2. When the throttle volume is operated
g) Back-up operation g) Back-up operation
1. Sensor trouble 1. Sensor trouble
If trouble occurs in a sensor (upper, travel, swing, arm-in, coolant temperature sensor), auto warm up is If trouble occurs in a sensor (upper, travel, swing, arm-in, coolant temperature sensor), auto warm up is
not operated. Also, even trouble occurs in a sensor partway through a warm up, the warm up is ended not operated. Also, even trouble occurs in a sensor partway through a warm up, the warm up is ended
and operation shifts to normal control. and operation shifts to normal control.
2. One-touch idle switch trouble 2. One-touch idle switch trouble
Even if the switch is pressed, auto warm up is not ended. Even if the switch is pressed, auto warm up is not ended.
3. Throttle volume trouble 3. Throttle volume trouble
Even if the throttle volume is operated, the auto warm up is not ended Even if the throttle volume is operated, the auto warm up is not ended

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Engine Start / Stop Control Engine Start / Stop Control
1. Engine Start / Stop Judgment 1. Engine Start / Stop Judgment
a) Configuration a) Configuration

Engine Engine
Speed Speed
Engine Engine

ECM ECM

1 Computer A 1 Computer A
2 Cam sensor 2 Cam sensor
3 Crank sensor 3 Crank sensor

b) Summary b) Summary
Engine start and stop is judged based on the engine speed sent from the ECM with CAN communications. Engine start and stop is judged based on the engine speed sent from the ECM with CAN communications.
c) Judgment value c) Judgment value
Start 500 min-1, Stop 200 min-1 Start 500 min-1, Stop 200 min-1
Start Start

Stop Stop
200 min-1 500 min-1 200 min-1 500 min-1

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2. Power-Cut Delay 2. Power-Cut Delay


a) Configuration (fuses etc. omitted) a) Configuration (fuses etc. omitted)

1 Computer A 5 Load A 1 Computer A 5 Load A


2 Key switch 6 Power supply 2 Key switch 6 Power supply
3 Battery relay 7 Key switch signal 3 Battery relay 7 Key switch signal
4 Battery 8 Battery relay hold 4 Battery 8 Battery relay hold

b) Summary b) Summary
After the key is switched OFF, after the battery relay is held for a certain period, the power supply is cut off. After the key is switched OFF, after the battery relay is held for a certain period, the power supply is cut off.
c) Purpose c) Purpose
1. This secures time after the key is switched OFF for data to be written in the EEPROM in the ECM and 1. This secures time after the key is switched OFF for data to be written in the EEPROM in the ECM and
Computer A. Computer A.
2. This waits until the engine completely stops to avoid load dumping. 2. This waits until the engine completely stops to avoid load dumping.
d) Operation d) Operation
1. When the key is ON, the battery relay is held by the battery relay hold output (OUT1) from the ECM and 1. When the key is ON, the battery relay is held by the battery relay hold output (OUT1) from the ECM and
the key switch. the key switch.
2. After the key is switched OFF, the battery relay is only held by the ECM. 2. After the key is switched OFF, the battery relay is only held by the ECM.
3. After it detects the key going OFF through the key switch signal input (IN1), the ECM starts the count 3. After it detects the key going OFF through the key switch signal input (IN1), the ECM starts the count
down. down.
4. After a certain time has passed, the ECM stops output to the battery relay and the battery relay goes 4. After a certain time has passed, the ECM stops output to the battery relay and the battery relay goes
OFF. OFF.
At the same time, the power supply to electrical parts, including the ECM and computer is cut (Except At the same time, the power supply to electrical parts, including the ECM and computer is cut (Except
the backup power supply). the backup power supply).
5. The time from the key being switched OFF until the power supply goes OFF (the delay time) depends on 5. The time from the key being switched OFF until the power supply goes OFF (the delay time) depends on
whether or not the engine was started. whether or not the engine was started.
• After the key is switched ON, if the key is switched OFF without the engine being started = about 4 • After the key is switched ON, if the key is switched OFF without the engine being started = about 4
seconds. seconds.
• If the key is switched OFF after the engine was started = about 7 seconds. • If the key is switched OFF after the engine was started = about 7 seconds.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-17 4001-17

3. Engine Emergency Stop 3. Engine Emergency Stop


Function for stopping the engine in an emergency Function for stopping the engine in an emergency
When the emergency stop switch on top of the left console is pressed, the engine is stopped regardless of the When the emergency stop switch on top of the left console is pressed, the engine is stopped regardless of the
key switch position. key switch position.

1 Monitor display 3 Engine 1 Monitor display 3 Engine


2 Computer A 4 Emergency stop switch 2 Computer A 4 Emergency stop switch

a) Circuit a) Circuit
1. When the emergency stop switch is pressed, a 24 V signal enters the ECM input port. 1. When the emergency stop switch is pressed, a 24 V signal enters the ECM input port.
2. When the 1) signal enters, the ECM controls the injector, suction control valve, and EGR valve to stop 2. When the 1) signal enters, the ECM controls the injector, suction control valve, and EGR valve to stop
the engine. the engine.
3. The emergency stop switch signal enters computer A too and computer A sends the engine stop 3. The emergency stop switch signal enters computer A too and computer A sends the engine stop
command to the ECM with CAN communications. command to the ECM with CAN communications.
4. At the same time, computer A sends the emergency stop and buzzer instructions to the monitor with 4. At the same time, computer A sends the emergency stop and buzzer instructions to the monitor with
serial communications. serial communications.
b) Display, alarm b) Display, alarm
1. When the emergency stop switch is switched ON, the "ENGINE STOP" message is displayed on the 1. When the emergency stop switch is switched ON, the "ENGINE STOP" message is displayed on the
monitor. monitor.
2. Even if there is another message, the "ENGINE STOP" message is displayed with priority for five 2. Even if there is another message, the "ENGINE STOP" message is displayed with priority for five
seconds after the switch is switched ON. seconds after the switch is switched ON.
3. At the same time as 1), the buzzer in the monitor buzzes intermittently at 1 Hz. 3. At the same time as 1), the buzzer in the monitor buzzes intermittently at 1 Hz.
4. If any kind of trouble is detected during the 1 Hz intermittent buzzing of 3), after the 5-second continuous 4. If any kind of trouble is detected during the 1 Hz intermittent buzzing of 3), after the 5-second continuous
buzzing, which is the trouble alarm, the buzzing returns to the 1 Hz intermittent buzzing. buzzing, which is the trouble alarm, the buzzing returns to the 1 Hz intermittent buzzing.
5. Even if the buzzing continues after the switch ON/OFF message display (for 5 seconds), the message 5. Even if the buzzing continues after the switch ON/OFF message display (for 5 seconds), the message
display is not extended. display is not extended.
6. The above message display and buzzer operate whether the engine is running or stopped. 6. The above message display and buzzer operate whether the engine is running or stopped.

c) An emergency stop takes priority over any other control and stops the engine. c) An emergency stop takes priority over any other control and stops the engine.
• The engine stops even during lifting magnet suction, during elevator cab rising, and fan reverse • The engine stops even during lifting magnet suction, during elevator cab rising, and fan reverse
operation (large machine only). operation (large machine only).
d) When an emergency stop is made, it is not recorded in the trouble log. d) When an emergency stop is made, it is not recorded in the trouble log.
e) The engine can be cranked with the emergency stop switch ON, but the engine will not start. e) The engine can be cranked with the emergency stop switch ON, but the engine will not start.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-18 4001-18

4. Neutral Start 4. Neutral Start


a) Purpose and summary a) Purpose and summary
The engine will not start with the gate lever lifted (It will not crank). The engine will not start with the gate lever lifted (It will not crank).
This prevents accidental operation if the operation lever is accidentally bumped into when the engine is This prevents accidental operation if the operation lever is accidentally bumped into when the engine is
started. started.
b) Configuration b) Configuration

Gate lever Gate lever

Down (OFF) Down (OFF)

Up (ON) Up (ON)

1 Key switch 5 Starter cut relay 1 Key switch 5 Starter cut relay
2 Gate lock limit switch 6 Lever lock solenoid 2 Gate lock limit switch 6 Lever lock solenoid
3 Starter motor 7 Battery relay 3 Starter motor 7 Battery relay
4 Safety relay 4 Safety relay

c) Operation c) Operation
When the gate lever is raised (and the limit switch comes ON), the starter cut relay is excited, the excitation When the gate lever is raised (and the limit switch comes ON), the starter cut relay is excited, the excitation
to the safety relay is cut off, and the engine does not crank. At this time, nothing in particular is displayed to the safety relay is cut off, and the engine does not crank. At this time, nothing in particular is displayed
on the monitor. on the monitor.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-19 4001-19
Pump Control Pump Control
1. Work Mode Control 1. Work Mode Control
a) Purpose: a) Purpose:
Work mode control enables the operator to select the work mode to match the work contents, for example Work mode control enables the operator to select the work mode to match the work contents, for example
emphasizing speed, emphasizing fuel economy, etc. emphasizing speed, emphasizing fuel economy, etc.
At the same time, the engine speed is adjusted (throttle adjustment). At the same time, the engine speed is adjusted (throttle adjustment).

Work mode display Work mode display

Work mode display Work mode display

Target engine speed Target engine speed

ECM ECM

1 Monitor 6 Boost solenoid 1 Monitor 6 Boost solenoid


2 Computer A 7 P1 pressure sensor 2 Computer A 7 P1 pressure sensor
3 Engine 8 P2 pressure sensor 3 Engine 8 P2 pressure sensor
4 Throttle volume 9 N1 pressure sensor 4 Throttle volume 9 N1 pressure sensor
5 Pump horsepower control proportional valve 10 N2 pressure sensor 5 Pump horsepower control proportional valve 10 N2 pressure sensor

b) Operation: b) Operation:
1. Manual switchover (main mode) 1. Manual switchover (main mode)
The operator can select one of the following work modes by turning the throttle volume. The operator can select one of the following work modes by turning the throttle volume.
For the correspondence between the throttle volume detents and the work modes, see the attached For the correspondence between the throttle volume detents and the work modes, see the attached
table. table.

Mode Aim Display Monitor buzzer Mode Aim Display Monitor buzzer
The buzzer buzzes twice when The buzzer buzzes twice when
(1) SP mode Speed emphasis (1) SP mode Speed emphasis
this is selected. this is selected.

Balances speed and The buzzer buzzes once when Balances speed and The buzzer buzzes once when
(2) H mode (2) H mode
fuel economy this is selected. fuel economy this is selected.

Fuel economy Fuel economy


(3) A mode No buzzing (3) A mode No buzzing
emphasis emphasis

2. Automatic switchover (submode) 2. Automatic switchover (submode)


Each of the main modes that can be selected manually has two sub-modes (high and low). Each of the main modes that can be selected manually has two sub-modes (high and low).
These sub-modes are switched automatically based on the sensor input values. These sub-modes are switched automatically based on the sensor input values.
For the high and low milli-amps, refer to the explanation of the 2. Pump Horsepower Boost Control in For the high and low milli-amps, refer to the explanation of the 2. Pump Horsepower Boost Control in
next page. next page.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-20 4001-20
2. Pump Horsepower Boost Control 2. Pump Horsepower Boost Control
a) Purpose: a) Purpose:
To prevent drop in the engine speed when the lever is operated sharply, when there is high load, when To prevent drop in the engine speed when the lever is operated sharply, when there is high load, when
travelling, etc. travelling, etc.

Control milli-amp Control milli-amp


Volume position (detent position) 1 2 3 4 to 8 9 to 15 Volume position (detent position) 1 2 3 4 to 8 9 to 15
Work mode SP H AUTO Work mode SP H AUTO
1499 to 1499 to
Engine speed (min-1) 2000 1850 1700 1699 to 1500 Engine speed (min-1) 2000 1850 1700 1699 to 1500
1050 1050
Milli-amp for pump Max High 600 531 531 213 50 Milli-amp for pump Max High 600 531 531 213 50
horsepower control Max Low 571 491 491 213 50 horsepower control Max Low 571 491 491 213 50
proportional valve (mA) Min 213 213 21 213 50 proportional valve (mA) Min 213 213 21 213 50
Boosted pressure Automatic Automatic Normal Boosted pressure Automatic Automatic Normal

b) Operation: b) Operation:
1. Reduces the amount of speed drop under high load (SP-H mode) 1. Reduces the amount of speed drop under high load (SP-H mode)
Operation conditions => For high load Operation conditions => For high load
When the P1 + P2 pressure becomes high voltage, the milli-amp to the pump horsepower control When the P1 + P2 pressure becomes high voltage, the milli-amp to the pump horsepower control
proportional valve Imax is changed Low => High to increase the pump flow. proportional valve Imax is changed Low => High to increase the pump flow.
2. Reduces the amount of speed drop under high load when digging with the arm-in (SP-H mode) 2. Reduces the amount of speed drop under high load when digging with the arm-in (SP-H mode)
When the arm-in operation is detected by the arm-in pilot pressure sensor, high load is detected faster When the arm-in operation is detected by the arm-in pilot pressure sensor, high load is detected faster
than for other operations. than for other operations.
3. Rise speed up for sharp lever operation 3. Rise speed up for sharp lever operation
Operation conditions => For sharp lever operation Operation conditions => For sharp lever operation
When sharp lever operation is detected by the N1 or N2 negative control pressure sensor, the milli-amp When sharp lever operation is detected by the N1 or N2 negative control pressure sensor, the milli-amp
to the pump horsepower control proportional valve Imax is changed Low => High to increase the pump to the pump horsepower control proportional valve Imax is changed Low => High to increase the pump
flow. flow.
4. For travel operation 4. For travel operation
For travel operation, the pump milli-amp is fixed to 600 mA. For travel operation, the pump milli-amp is fixed to 600 mA.
However, if the engine speed is 1500 min-1 or less, the pump milli-amp is fixed to 50 mA (Prevention of However, if the engine speed is 1500 min-1 or less, the pump milli-amp is fixed to 50 mA (Prevention of
engine stalling is given priority). engine stalling is given priority).

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-21 4001-21

3. Pump Horsepower Cut Control 3. Pump Horsepower Cut Control


a) Purpose: a) Purpose:
The pump milli-amp is controlled in order to prevent black smoke under overload and engine speed drop and The pump milli-amp is controlled in order to prevent black smoke under overload and engine speed drop and
in order to improve energy saving. in order to improve energy saving.
The control methods are the following three. The control methods are the following three.
1. Overload reduction control 1. Overload reduction control
2. Engine stalling prevention control 2. Engine stalling prevention control
3. PID control 3. PID control

ECM ECM

1 Computer A 4 P1 pressure sensor 1 Computer A 4 P1 pressure sensor


2 Pump 5 P2 pressure sensor 2 Pump 5 P2 pressure sensor
3 Engine 6 Pump horsepower control proportional valve 3 Engine 6 Pump horsepower control proportional valve

b) Overload reduction control b) Overload reduction control


When the engine is under overload, the milli-amp to the pump horsepower proportional valve first drops to When the engine is under overload, the milli-amp to the pump horsepower proportional valve first drops to
50mA. 50mA.
After that, the milli-amp is gradually raised while watching the difference between the actual engine speed After that, the milli-amp is gradually raised while watching the difference between the actual engine speed
and the target engine speed. and the target engine speed.
Overload reduction control is executed in all work modes. Overload reduction control is executed in all work modes.
• The engine is judged to be overloaded when the following conditions are met. • The engine is judged to be overloaded when the following conditions are met.
1. Sharp lever operation 1. Sharp lever operation
When there is sharp lever operation, this is judged from the upper pressure sensor state. When there is sharp lever operation, this is judged from the upper pressure sensor state.
2. Operation for high loads and sharp loads 2. Operation for high loads and sharp loads
Judged from the P1 or P2 pump pressure sensor and from the pump main pressure boost state. Judged from the P1 or P2 pump pressure sensor and from the pump main pressure boost state.
c) Engine stalling prevention control c) Engine stalling prevention control
When the target engine speed is 1300 min-1 or less, the milli-amp is 50 mA. When the target engine speed is 1300 min-1 or less, the milli-amp is 50 mA.
d) PID control d) PID control
When the engine actual speed falls 30 min -1 or more below the target engine speed, the milli-amp is When the engine actual speed falls 30 min -1 or more below the target engine speed, the milli-amp is
gradually lowered to I Min. gradually lowered to I Min.
When the difference of the actual engine speed from the target engine speed falls below 30 min-1 the milli- When the difference of the actual engine speed from the target engine speed falls below 30 min-1 the milli-
amp rises to the I Max High for the each mode. amp rises to the I Max High for the each mode.
Backup control Backup control
If trouble occurs in a pressure sensor (P1, P2, upper), the overload restriction control is not carried out. If trouble occurs in a pressure sensor (P1, P2, upper), the overload restriction control is not carried out.
If trouble occurs in the pump horsepower control proportional valve, the output from the computer stops. If trouble occurs in the pump horsepower control proportional valve, the output from the computer stops.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-22 4001-22
Swing Swing
1. Swing Brake 1. Swing Brake
a) Configuration a) Configuration

For North For North


America America

Engine actual Engine actual


speed speed

1 Horn volume select switch 8 Swing brake solenoid 1 Horn volume select switch 8 Swing brake solenoid
2 Computer A 9 Accumulator 2 Computer A 9 Accumulator
3 Engine 10 Swing Motor 3 Engine 10 Swing Motor
4 Working light switch 11 Swing Brake 4 Working light switch 11 Swing Brake
5 Auto idle switch 12 Free swing solenoid 5 Auto idle switch 12 Free swing solenoid
6 Upper pressure sensor 13 Free swing switch (momentary) 6 Upper pressure sensor 13 Free swing switch (momentary)
7 Swing pressure sensor 7 Swing pressure sensor

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-23 4001-23
b) Braking function during upper operation b) Braking function during upper operation
When the upper pressure sensor is ON, the brake goes OFF, one second after upper pressure sensor goes When the upper pressure sensor is ON, the brake goes OFF, one second after upper pressure sensor goes
OFF, the brake comes ON. OFF, the brake comes ON.
c) Braking control through swing operation c) Braking control through swing operation
When the swing pressure sensor is ON, the swing brake goes OFF (Swing brake solenoid = OFF). When the swing pressure sensor is ON, the swing brake goes OFF (Swing brake solenoid = OFF).
Five seconds after the swing pressure goes OFF, the swing brake comes ON (Swing brake solenoid = ON). Five seconds after the swing pressure goes OFF, the swing brake comes ON (Swing brake solenoid = ON).
d) Swing lock with key OFF d) Swing lock with key OFF
When the key is OFF (during power-cut delay), the swing brake comes ON unconditionally When the key is OFF (during power-cut delay), the swing brake comes ON unconditionally
. .
Power-cut delay Power-cut delay
b) c) b), c) d) b) c) b), c) d)

1 second 5 seconds 5 seconds 1 second 5 seconds 5 seconds


1 second 1 second
Swing brake Swing brake
solenoid solenoid

Upper pressure Upper pressure


sensor sensor

Swing pressure Swing pressure


sensor sensor

Engine state Engine state

Key switch Key switch

2. Free Swing (North America Only) 2. Free Swing (North America Only)
a) Free swing switchover a) Free swing switchover
When the free swing switch is pressed, the free swing mode is switched ON <=> OFF. When the When the free swing switch is pressed, the free swing mode is switched ON <=> OFF. When the
(momentary) key is OFF, always start with free swing OFF (Previous data reset). (momentary) key is OFF, always start with free swing OFF (Previous data reset).
b) Free swing control b) Free swing control
When free swing is ON, the free swing solenoid is ON and the swing brake solenoid is OFF. When free swing is ON, the free swing solenoid is ON and the swing brake solenoid is OFF.
c) Mode display c) Mode display
When free swing is ON, the icon in the figure below is displayed on the monitor. When free swing is ON, the icon in the figure below is displayed on the monitor.
d) Battery save d) Battery save
While the engine is stopped with the key ON, if free swing is switched ON, the icon is displayed, but the While the engine is stopped with the key ON, if free swing is switched ON, the icon is displayed, but the
free swing solenoid valve does not come ON. It does come ON after the engine starts. free swing solenoid valve does not come ON. It does come ON after the engine starts.

Free swing Free swing

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-24 4001-24

3. Swing Lock (for maintenance) 3. Swing Lock (for maintenance)


This is used for measuring the swing relief pressure and other maintenance tasks. This is used for measuring the swing relief pressure and other maintenance tasks.
a) Swing lock switching a) Swing lock switching
In order to prevent accidental operation under certain special circumstances, sometimes the swing brake In order to prevent accidental operation under certain special circumstances, sometimes the swing brake
need to be left ON all the time. "Swing lock" At this time, the swing lock can be switched ON / OFF by need to be left ON all the time. "Swing lock" At this time, the swing lock can be switched ON / OFF by
holding down the "horn volume select switch", the "working light switch", and the "auto idle switch" at the holding down the "horn volume select switch", the "working light switch", and the "auto idle switch" at the
same time for 3 seconds. same time for 3 seconds.
When turning the key to ON, always start with the swing lock OFF (Previous data reset). When turning the key to ON, always start with the swing lock OFF (Previous data reset).
b) Swing lock control b) Swing lock control
When the swing lock is ON, even if the upper or the swing is operated, the swing brake keep working. Be When the swing lock is ON, even if the upper or the swing is operated, the swing brake keep working. Be
particularly careful about swing operation because the swing brake plate is dragged. particularly careful about swing operation because the swing brake plate is dragged.
(The swing pilot pressure is not shut off. This is no more than a simple swing lock). (The swing pilot pressure is not shut off. This is no more than a simple swing lock).
c) Competition with free swing c) Competition with free swing
If the swing lock is used, even if free swing is ON, the swing brake solenoid comes ON and the free swing If the swing lock is used, even if free swing is ON, the swing brake solenoid comes ON and the free swing
solenoid goes OFF (Swing lock priority). solenoid goes OFF (Swing lock priority).
d) Mode display d) Mode display
When free swing is ON, the icon in the figure below is displayed on the monitor. When free swing is ON, the icon in the figure below is displayed on the monitor.

Swing lock Swing lock

e) Time chart (free swing & swing lock) e) Time chart (free swing & swing lock)
Power-cut Power-cut Power-cut Power-cut
delay delay delay delay

Swing brake Swing brake


solenoid solenoid

Free swing Free swing


solenoid solenoid

Engine state Engine state

Key swing Key swing

Free swing Free swing

Swing lock Swing lock

3-b) 3-c) 2-a) 3-a) 3-b) 3-c) 2-a) 3-a)


2-d) The Previous 2-d) The Previous
data is hold data is hold
f) Trouble mode f) Trouble mode
If trouble occurs in an input (upper / swing pressure sensor), communications (CAN), or output (swing If trouble occurs in an input (upper / swing pressure sensor), communications (CAN), or output (swing
brake solenoid / free swing solenoid), the system goes into trouble mode. In trouble mode, the swing brake brake solenoid / free swing solenoid), the system goes into trouble mode. In trouble mode, the swing brake
solenoid is OFF and the free swing solenoid is OFF. Even if the trouble is recovered from, this does not solenoid is OFF and the free swing solenoid is OFF. Even if the trouble is recovered from, this does not
recover the system from trouble mode. recover the system from trouble mode.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-25 4001-25
4. Swing Relief Cut 4. Swing Relief Cut
Purpose: Purpose:
When swing single operation is running, the pump flow is reduced, and the excess oil ejected from the swing When swing single operation is running, the pump flow is reduced, and the excess oil ejected from the swing
motor relief valve is eliminated. motor relief valve is eliminated.

1 Computer A 8 Option 15 Travel (right) 1 Computer A 8 Option 15 Travel (right)


2 Throttle volume 9 Boom 2 16 Straight travel 2 Throttle volume 9 Boom 2 16 Straight travel
3 Travel pressure sensor 10 Swing 17 P1 pressure sensor 3 Travel pressure sensor 10 Swing 17 P1 pressure sensor
4 Option 1 pressure switch 11 Travel (left) 18 P2 pressure sensor 4 Option 1 pressure switch 11 Travel (left) 18 P2 pressure sensor
5 N1 pressure sensor 12 Arm (2) 19 Regulator 5 N1 pressure sensor 12 Arm (2) 19 Regulator
6 N2 pressure sensor 13 Bucket 20 P1 flow control proportional valve 6 N2 pressure sensor 13 Bucket 20 P1 flow control proportional valve
7 Arm (1) 14 Boom (1) 7 Arm (1) 14 Boom (1)

Operation explanation: Operation explanation:


a) Operation conditions for swing relief cut control a) Operation conditions for swing relief cut control
The swing relief cut control provides relief when the pressure is boosted for the start of the swing due to The swing relief cut control provides relief when the pressure is boosted for the start of the swing due to
sharp swing operation and the drained off excess oil is held to the lowest amount possible. The purpose is sharp swing operation and the drained off excess oil is held to the lowest amount possible. The purpose is
to provide an energy saving effect. to provide an energy saving effect.
Control is executed when all the conditions below are satisfied. Control is executed when all the conditions below are satisfied.
1. Sharp swing operation => When the swing lever is operated, this is judged from the swing pilot pressure 1. Sharp swing operation => When the swing lever is operated, this is judged from the swing pilot pressure
sensor pressure rise. sensor pressure rise.
2. Within 1 second after start of swing 2. Within 1 second after start of swing
3. Travel non-operation => Travel pressure sensor OFF 3. Travel non-operation => Travel pressure sensor OFF
4. No attachments other than boom down are operating. 4. No attachments other than boom down are operating.
• That no attachment is operating is judged from the N2 negative control pressure and P1 pressure • That no attachment is operating is judged from the N2 negative control pressure and P1 pressure
sensor. sensor.
5. Option line non-operation => Option pressure sensor OFF 5. Option line non-operation => Option pressure sensor OFF

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-26 4001-26
b) Control contents b) Control contents
For the swing relief cut operation, after the milli-amp to the P1 flow control proportional valve is increased For the swing relief cut operation, after the milli-amp to the P1 flow control proportional valve is increased
and the P1 flow is reduced, while checking the P1 pump discharge pressure, the system gradually reduces and the P1 flow is reduced, while checking the P1 pump discharge pressure, the system gradually reduces
the output milli-amp to the P1 flow control valve and raises the P1 pump flow to the constant swing speed. the output milli-amp to the P1 flow control valve and raises the P1 pump flow to the constant swing speed.
• Swing relief cut control flow • Swing relief cut control flow
Judged as swing single operation + sharp operation => Swing relief cut operation => Increased milli-amp Judged as swing single operation + sharp operation => Swing relief cut operation => Increased milli-amp
to P1 flow control proportional valve. to P1 flow control proportional valve.
=> P1 pump flow reduced => Milli-amp gradually decreased while watching swing pressure fall status => => P1 pump flow reduced => Milli-amp gradually decreased while watching swing pressure fall status =>
P1 pump flow increased P1 pump flow increased
NOTE: P1 flow control proportional valve: milli-amp (high) => P1 pump flow (low); milli-amp (low) => P1 NOTE: P1 flow control proportional valve: milli-amp (high) => P1 pump flow (low); milli-amp (low) => P1
pump flow (high) pump flow (high)
c) Swing relief cut end conditions c) Swing relief cut end conditions
1. When swing operation is stopped 1. When swing operation is stopped
2. Travel ON 2. Travel ON
3. Boom up, arm out / in, bucket open / closed 3. Boom up, arm out / in, bucket open / closed
4. Boom down sharp operation 4. Boom down sharp operation
5. Boom down pressure boost 5. Boom down pressure boost

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-27 4001-27
Travel Travel
1. Travel Speed Switchover 1. Travel Speed Switchover
The travel motor tilt revolution angle is changed by switching the travel speed between low speed and high The travel motor tilt revolution angle is changed by switching the travel speed between low speed and high
speed with the switch. speed with the switch.
However, in high-speed mode, if the drive force becomes high due to the functioning of the travel motor itself, However, in high-speed mode, if the drive force becomes high due to the functioning of the travel motor itself,
the tilt revolution angle is automatically switched to low speed. the tilt revolution angle is automatically switched to low speed.
After that, when the drive force becomes low, the slope automatically returns to high speed. After that, when the drive force becomes low, the slope automatically returns to high speed.

Switch data Switch data

Engine actual speed Engine actual speed

1 Computer A 4 Travel motor 1 Computer A 4 Travel motor


2 Engine 5 Travel high-speed solenoid 2 Engine 5 Travel high-speed solenoid
3 Travel high-speed select switch 6 Key switch 3 Travel high-speed select switch 6 Key switch

a) Operation a) Operation
1. When the key is ON, the speed becomes low speed. The previous travel mode is reset. 1. When the key is ON, the speed becomes low speed. The previous travel mode is reset.
(If the service support operation is changed, it is possible to hold the previous data). (If the service support operation is changed, it is possible to hold the previous data).
2. Each time the travel high-speed switch is pressed, the speed is switched between low speed and high 2. Each time the travel high-speed switch is pressed, the speed is switched between low speed and high
speed. During high speed, the LED at the top left of the switch lights up. speed. During high speed, the LED at the top left of the switch lights up.
3. While the engine is stopped with the key ON, if the high speed travel switch is pressed, the solenoid 3. While the engine is stopped with the key ON, if the high speed travel switch is pressed, the solenoid
does not operate. The LED lights up. does not operate. The LED lights up.
(To prevent the battery being run down). (To prevent the battery being run down).
4. In high-speed mode, the tilt revolution angle is automatically switched between low speed and high 4. In high-speed mode, the tilt revolution angle is automatically switched between low speed and high
speed by the travel motor drive force. speed by the travel motor drive force.
However, the electrical control remains at high speed, the high-speed LED remains lit, and the solenoid However, the electrical control remains at high speed, the high-speed LED remains lit, and the solenoid
remains ON. remains ON.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-28 4001-28
b) Trouble mode b) Trouble mode
If an abnormality occurs in communications (CAN) or computer solenoid output, the speed is fixed to low If an abnormality occurs in communications (CAN) or computer solenoid output, the speed is fixed to low
speed (The travel high-speed solenoid comes OFF). speed (The travel high-speed solenoid comes OFF).

Key switch Key switch

Engine Engine

Travel high-speed Travel high-speed


switch switch

LED LED

Travel high-speed Travel high-speed


solenoid solenoid

High speed High speed


Travel motor Travel motor
Low speed Low speed
Drive voltage rise Drive voltage rise
Drive voltage fall Drive voltage fall

2. Travel Alarm (North America only) 2. Travel Alarm (North America only)
a) Configuration a) Configuration

Travel alarm Travel alarm

Intermittent buzzing control is handled by Intermittent buzzing control is handled by


the travel alarm itself. In other words, while the travel alarm itself. In other words, while
the travel alarm is ON, computer A buzzes the travel alarm is ON, computer A buzzes
the buzzer intermittently as it wants. the buzzer intermittently as it wants.

For North For North


America: America:
Standard Standard

1 Computer A Travel alarm mode select switch (alternator) 1 Computer A Travel alarm mode select switch (alternator)
3 3
2 Travel pressure sensor 2 Travel pressure sensor

b) Travel alarm (automatic stop) b) Travel alarm (automatic stop)


When the travel pressure sensor comes ON due to travel operation, the travel alarm starts 1 Hz intermittent When the travel pressure sensor comes ON due to travel operation, the travel alarm starts 1 Hz intermittent
buzzing. This buzzing automatically stops after 10 seconds. buzzing. This buzzing automatically stops after 10 seconds.
c) Travel alarm (continuous buzzing) c) Travel alarm (continuous buzzing)
When the travel alarm mode select switch is switched ON, the buzzer buzzes continuously during travel When the travel alarm mode select switch is switched ON, the buzzer buzzes continuously during travel
(Function for North America only). (Function for North America only).
d) Signals when key is ON d) Signals when key is ON
After the key is switched ON, the travel alarm sounds for 0.4 second as a signal. After the key is switched ON, the travel alarm sounds for 0.4 second as a signal.

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4001-29 4001-29
e) Time chart e) Time chart

0.4 seconds 10 seconds 0.4 seconds 10 seconds


10 seconds 10 seconds 10 seconds 10 seconds

ON ON
Travel alarm Travel alarm
OFF OFF

Travel pressure ON Travel pressure ON


sensor sensor
OFF OFF

ON ON
Key switch Key switch
OFF OFF

Travel alarm ON Travel alarm ON


mode select mode select
switch OFF switch OFF

d) b) c) Mode switchover d) b) c) Mode switchover


during travel during travel

f) Trouble mode f) Trouble mode


If trouble occurs in the travel pressure sensor, the machine goes into trouble mode and the travel alarm is If trouble occurs in the travel pressure sensor, the machine goes into trouble mode and the travel alarm is
always OFF. always OFF.

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4001-30 4001-30
Valve Control Valve Control
1. Lever Lock 1. Lever Lock

Gate lever Gate lever


Down (OFF) Down (OFF)

UP (ON) UP (ON)

1 Gate lock limit switch 3 Lever lock solenoid 1 Gate lock limit switch 3 Lever lock solenoid
2 Starter cut relay 4 Battery relay 2 Starter cut relay 4 Battery relay

Operation explanation: Operation explanation:


When the battery relay is excited by the key being switched ON, the power enters the lever lock limit When the battery relay is excited by the key being switched ON, the power enters the lever lock limit
switch. When the gate lever is raised, the lever lock switch (limit switch) comes ON and the lever lock switch. When the gate lever is raised, the lever lock switch (limit switch) comes ON and the lever lock
solenoid is operated (For details on neutral start control, see Neutral Start in Explanation of Functions and solenoid is operated (For details on neutral start control, see Neutral Start in Explanation of Functions and
Operations). Operations).

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4001-31 4001-31

2. Solenoid Sticking Prevention 2. Solenoid Sticking Prevention


a) Target solenoid a) Target solenoid
• Travel high-speed switchover solenoid • Travel high-speed switchover solenoid
• Boost solenoid • Boost solenoid
• Option switchover solenoid • Option switchover solenoid
• Fan reverse solenoid (only for models with hydraulic drive fan) • Fan reverse solenoid (only for models with hydraulic drive fan)
• Free swing solenoid • Free swing solenoid
• Bucket lock solenoid (only lift crane application machines) • Bucket lock solenoid (only lift crane application machines)
Because the swing brake, power save solenoid, and electromagnetic proportional solenoid go ON and Because the swing brake, power save solenoid, and electromagnetic proportional solenoid go ON and
OFF frequently in regular work, they are not subject to control. OFF frequently in regular work, they are not subject to control.
b) Operation b) Operation
When key ON, switched ON / OFF for 0.25 second. When key ON, switched ON / OFF for 0.25 second.
After that, control is normal control. Control ends before the engine starts, so the machine does not operate After that, control is normal control. Control ends before the engine starts, so the machine does not operate
accidentally. accidentally.
ON ON
Key switch Key switch
OFF OFF

ON Normal control ON Normal control


Solenoid Solenoid
OFF OFF

0.25 second0.25 second 0.25 second0.25 second

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4001-32 4001-32

3. Pressure Boost Control 3. Pressure Boost Control


a) Configuration a) Configuration

Message and icon Message and icon

Engine load rate Engine load rate

1 Computer A 6 2nd option line pressure switch 11 P2 pressure sensor 1 Computer A 6 2nd option line pressure switch 11 P2 pressure sensor
2 Engine 7 Control valve 12 Pump 1 2 Engine 7 Control valve 12 Pump 1
3 Upper pressure sensor 8 Main relief valve 13 Pump 2 3 Upper pressure sensor 8 Main relief valve 13 Pump 2
4 Travel pressure sensor 9 Boost solenoid 14 Regulator 4 Travel pressure sensor 9 Boost solenoid 14 Regulator
5 Option line pressure switch 10 P1 pressure sensor 5 Option line pressure switch 10 P1 pressure sensor

b) During upper operation (upper pressure sensor = ON), the next time the high-load conditions are met, the boost b) During upper operation (upper pressure sensor = ON), the next time the high-load conditions are met, the boost
solenoid valve on the 5 stack solenoid valve comes ON, and the main relief valve pressure rises from 34.3 MPa solenoid valve on the 5 stack solenoid valve comes ON, and the main relief valve pressure rises from 34.3 MPa
(343 bar / 4975 psi) to 36.8 MPa (369 bar / 5337 psi). (343 bar / 4975 psi) to 36.8 MPa (369 bar / 5337 psi).
Conditions: Conditions:
When the engine load ratio rises and the P1 or P2 pump pressure is boosted. When the engine load ratio rises and the P1 or P2 pump pressure is boosted.
c) Auto power boost (ended by time restriction) c) Auto power boost (ended by time restriction)
When the work mode is SP or H, the boost continues a maximum of 8 seconds, then is automatically ended When the work mode is SP or H, the boost continues a maximum of 8 seconds, then is automatically ended
(boost solenoid = OFF). When the work mode is A, this time restriction is eliminated and the pressure boost (boost solenoid = OFF). When the work mode is A, this time restriction is eliminated and the pressure boost
is always available. is always available.
d) Auto power boost (ended by operation stop) d) Auto power boost (ended by operation stop)
Even before the time limit for auto power boost, if the upper pressure sensor goes OFF, the boost is ended. Even before the time limit for auto power boost, if the upper pressure sensor goes OFF, the boost is ended.
e) Boost prohibition e) Boost prohibition
During travel (travel pressure sensor = ON) or the breaker is in use (option line pressure switch = ON During travel (travel pressure sensor = ON) or the breaker is in use (option line pressure switch = ON
and breaker mode), the boost is not used (Actuator protection). and breaker mode), the boost is not used (Actuator protection).

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4001-33 4001-33
f) Auto power boost setting f) Auto power boost setting
Auto pressure boost can be switched ON / OFF and boost for breaker operation enabled / disabled with Auto pressure boost can be switched ON / OFF and boost for breaker operation enabled / disabled with
service support operation. service support operation.
g) During boosting, the monitor displays an icon. g) During boosting, the monitor displays an icon.
. .

Icon Icon

h) Time chart (when work mode = SP or H) h) Time chart (when work mode = SP or H)
Less than 8 seconds Less than 8 seconds
0.1 second 8 seconds 0.1 second 0.1 second 0.1 second 0.1 second 8 seconds 0.1 second 0.1 second 0.1 second

Boost solenoid Boost solenoid

High-load conditions High-load conditions

Upper pressure Upper pressure


sensor sensor

Message and icon Message and icon

Travel pressure sensor Travel pressure sensor


OR / AND OR / AND
Option pressure sensor Option pressure sensor

c) d) e) b) c) d) e) b)
i) Trouble mode i) Trouble mode
If trouble occurs in an input (upper pressure sensor / travel pressure sensor), output (boost solenoid) or If trouble occurs in an input (upper pressure sensor / travel pressure sensor), output (boost solenoid) or
communications (CAN), the system goes into trouble mode. In trouble mode, the boost solenoid is fixed to communications (CAN), the system goes into trouble mode. In trouble mode, the boost solenoid is fixed to
OFF. OFF.
• Even if trouble occurs in UART communications, the system does not go into trouble mode. • Even if trouble occurs in UART communications, the system does not go into trouble mode.
• Trouble in the (2nd) option line pressure switch cannot be detected. • Trouble in the (2nd) option line pressure switch cannot be detected.
j) Recovery from trouble mode j) Recovery from trouble mode
Even if the trouble is recovered from, trouble mode continues. Even if the trouble is recovered from, trouble mode continues.

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4001-34 4001-34
Monitor Control Monitor Control
1. Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge) 1. Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge)
1) Coolant temperature gauge 1) Coolant temperature gauge
a) Configuration a) Configuration

Display data Display data

Coolant Coolant
temperature temperature
data data

. 8-level bar graph type . 8-level bar graph type

. Displayed on monitor LCD . Displayed on monitor LCD

Gauge . The left is the gauge level 3 display state. Gauge . The left is the gauge level 3 display state.
level level

1 Coolant temperature gauge 3 Computer A 1 Coolant temperature gauge 3 Computer A


2 Monitor 4 Coolant temperature sensor 2 Monitor 4 Coolant temperature sensor

b) Operation summary b) Operation summary


The ECM reads the coolant temperature from the coolant temperature sensor installed on the engine and The ECM reads the coolant temperature from the coolant temperature sensor installed on the engine and
send to computer A through CAN communication. After computer A receives the coolant temperature, it send to computer A through CAN communication. After computer A receives the coolant temperature, it
judges the gauge level, and sends the display data to the monitor with UART communications. judges the gauge level, and sends the display data to the monitor with UART communications.

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4001-35 4001-35
c) Gauge coolant temperature c) Gauge coolant temperature
The gauge level is judged based on the figure below. The gauge level is judged based on the figure below.
Gauge level Gauge level

Temperature Temperature

d) Preventing flickering d) Preventing flickering


When the temperature moves up or down near the gauge level fluctuation threshold (for example 51 °C When the temperature moves up or down near the gauge level fluctuation threshold (for example 51 °C
[124°F]), the gauge goes on and off repeatedly causing flickering. In order to prevent that, the gauge level [124°F]), the gauge goes on and off repeatedly causing flickering. In order to prevent that, the gauge level
is judged using the temperature (judgment coolant temperature) after the following processing. is judged using the temperature (judgment coolant temperature) after the following processing.
• Judgment coolant temperature = Average of the coolant temperatures obtained the past 32 times • Judgment coolant temperature = Average of the coolant temperatures obtained the past 32 times
• Coolant temperature obtained period = 1 second • Coolant temperature obtained period = 1 second
• Bar graph update period = 32 seconds (updates when the 32nd coolant temperature obtained) • Bar graph update period = 32 seconds (updates when the 32nd coolant temperature obtained)
e) Trouble mode e) Trouble mode
If trouble occurs in the coolant temperature sensor or CAN bus, the bar graph itself is not displayed. If trouble occurs in the coolant temperature sensor or CAN bus, the bar graph itself is not displayed.
1. If there is a short, the bar graph display is immediately ended. 1. If there is a short, the bar graph display is immediately ended.
2. For a disconnection, the display goes off 3 minutes after the engine starts. 2. For a disconnection, the display goes off 3 minutes after the engine starts.
If trouble occurs in UART communications (computer => monitor), the display is fixed at the last state sent. If trouble occurs in UART communications (computer => monitor), the display is fixed at the last state sent.
When the trouble is recovered from, the display returns to normal. When the trouble is recovered from, the display returns to normal.
For a disconnection, when the key is switched OFF more than three minutes after the engine starts, then For a disconnection, when the key is switched OFF more than three minutes after the engine starts, then
ON again, the display is recovered. ON again, the display is recovered.

Trouble Trouble

Recovery Recovery

Non-display state Non-display state


(oil temperature sensor (oil temperature sensor
breakdown) or CAN bus breakdown) or CAN bus

• Coolant temperature obtained during trouble: • Coolant temperature obtained during trouble:
If a meaningless coolant temperature were obtained and the processing in d) carried out, display upon If a meaningless coolant temperature were obtained and the processing in d) carried out, display upon
recovery would be strange. In order to prevent this, the coolant temperature is not obtained during a recovery would be strange. In order to prevent this, the coolant temperature is not obtained during a
coolant temperature sensor or CAN bus trouble. coolant temperature sensor or CAN bus trouble.
f) Message display f) Message display
When the gauge level reaches 8, "OVERHEAT" is displayed on the monitor and the buzzer buzzes. When the gauge level reaches 8, "OVERHEAT" is displayed on the monitor and the buzzer buzzes.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


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2) Oil temperature gauge 2) Oil temperature gauge


a) Configuration a) Configuration

<= Return <= Return

Display data Display data

=> suction (to pump) => suction (to pump)

. 8-Level bar graph type . 8-Level bar graph type

. display on monitor LCD . display on monitor LCD

Gauge level Gauge level


.The left is the gauge level 3 display state. .The left is the gauge level 3 display state.

1 Oil temperature gauge 4 Hydraulic oil tank 1 Oil temperature gauge 4 Hydraulic oil tank
2 Monitor 5 Oil temperature sensor 2 Monitor 5 Oil temperature sensor
3 Computer A 3 Computer A

b) Operation summary b) Operation summary


Computer A reads the oil temperature from the oil temperature sensor installed in the hydraulic oil tank Computer A reads the oil temperature from the oil temperature sensor installed in the hydraulic oil tank
outlet pipe and judges the gauge level. The gauge level is sent to the monitor with UART communications. outlet pipe and judges the gauge level. The gauge level is sent to the monitor with UART communications.

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4001-37 4001-37
c) Gauge and oil temperature c) Gauge and oil temperature
The gauge level is judged based on the figure below. The gauge level is judged based on the figure below.

Gauge level Gauge level

Oil temperature Oil temperature

d) Preventing flickering d) Preventing flickering


When the temperature moves up or down near the gauge level fluctuation threshold (for example 25 °C When the temperature moves up or down near the gauge level fluctuation threshold (for example 25 °C
[77°F]), the gauge goes on and off repeatedly causing flickering. In order to prevent that, the gauge level is [77°F]), the gauge goes on and off repeatedly causing flickering. In order to prevent that, the gauge level is
judged using the temperature (judgment oil temperature) after the following processing. judged using the temperature (judgment oil temperature) after the following processing.
• Judgment oil temperature = Average of the oil temperatures obtained the past 32 times • Judgment oil temperature = Average of the oil temperatures obtained the past 32 times
• Oil temperature obtained period = 1 second • Oil temperature obtained period = 1 second
• Bar graph update period = 32 seconds (updates when the 32nd oil temperature obtained) • Bar graph update period = 32 seconds (updates when the 32nd oil temperature obtained)
e) Trouble mode e) Trouble mode
If trouble occurs in the oil temperature sensor, the bar graph itself is not displayed (Only for trouble due to If trouble occurs in the oil temperature sensor, the bar graph itself is not displayed (Only for trouble due to
short). short).
If trouble occurs in UART communications (send: computer -> monitor), the display is fixed at the last state If trouble occurs in UART communications (send: computer -> monitor), the display is fixed at the last state
sent. sent.
When the trouble is recovered from, the display returns to normal. When the trouble is recovered from, the display returns to normal.

Trouble Trouble

Recovery Recovery

Non-display state Non-display state


(oil temperature sensor (oil temperature sensor
breakdown) breakdown)

• Oil temperature obtained during trouble. • Oil temperature obtained during trouble.
If a meaningless oil temperature were obtained and the processing in d) carried out, display upon If a meaningless oil temperature were obtained and the processing in d) carried out, display upon
recovery would be strange. In order to prevent this, the oil temperature is not obtained during an oil recovery would be strange. In order to prevent this, the oil temperature is not obtained during an oil
temperature sensor trouble. temperature sensor trouble.
f) Message display f) Message display
When the gauge level reaches 8, "OVERHEAT" is displayed on the monitor and the buzzer buzzes. When the gauge level reaches 8, "OVERHEAT" is displayed on the monitor and the buzzer buzzes.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-38 4001-38

3) Fuel gauge 3) Fuel gauge


a) Configuration a) Configuration

Full Full

Amount allowing Empty Amount allowing Empty


one more hour of one more hour of
work work

. 8-level bar graph type . 8-level bar graph type

. Displayed on monitor LCD . Displayed on monitor LCD

. The left is the gauge level 3 display state. . The left is the gauge level 3 display state.
Gauge level Gauge level

1 Monitor 3 Fuel tank 1 Monitor 3 Fuel tank


2 Computer A 4 Fuel sensor 2 Computer A 4 Fuel sensor

b) Operation summary b) Operation summary


Computer A reads the fuel level from the fuel sensor installed in the fuel tank and judges the gauge level. Computer A reads the fuel level from the fuel sensor installed in the fuel tank and judges the gauge level.
The gauge level is sent to the monitor with UART communications. The gauge level is sent to the monitor with UART communications.

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4001-39 4001-39
c) Relationship between gauge level and lever angle c) Relationship between gauge level and lever angle

Lever angle Lever angle


percentage % percentage %
Gauge level Gauge level

Overhead

Overhead
Rated Rated
Full Full

Reserve

Reserve
Reserve Reserve
Empty Empty

The remaining amount is measured The remaining amount is measured


from the top of the drain from the top of the drain

R: lever angle Percentage (%) R: lever angle Percentage (%)


Gauge level and fuel level (L) Gauge level and fuel level (L)
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
(R ≤ 0%) (R < 22%) (R < 38%) (R < 52%) (R < 67%) (R < 82%) (R < 100%) (R ≥ 100%) (R ≤ 0%) (R < 22%) (R < 38%) (R < 52%) (R < 67%) (R < 82%) (R < 100%) (R ≥ 100%)
≤ 21.9 < 59.9 < 96.8 < 132.7 < 172.3 < 210.1 < 247.8 ≥ 260.0 ≤ 21.9 < 59.9 < 96.8 < 132.7 < 172.3 < 210.1 < 247.8 ≥ 260.0

d) Message display d) Message display


When the gauge level reaches 1, "LOW FUEL" is displayed on the monitor and the buzzer buzzes (See When the gauge level reaches 1, "LOW FUEL" is displayed on the monitor and the buzzer buzzes (See
"Message Display List"). "Message Display List").
e) Preventing flickering e) Preventing flickering
When the fuel surface in the tank shakes and the fuel sensor lever angle moves up or down near the gauge When the fuel surface in the tank shakes and the fuel sensor lever angle moves up or down near the gauge
level fluctuation threshold (for example 7%), the gauge goes on and off repeatedly causing flickering. level fluctuation threshold (for example 7%), the gauge goes on and off repeatedly causing flickering.
In order to prevent that, the gauge level is judged using the lever angle (judgment lever angle) after the In order to prevent that, the gauge level is judged using the lever angle (judgment lever angle) after the
following processing. following processing.
• Lever angle acquisition period = 1 second • Lever angle acquisition period = 1 second
• Bar graph update period = 5 seconds • Bar graph update period = 5 seconds
• The judgment value when the bar graph is updated = average lever angle over the past 20 seconds • The judgment value when the bar graph is updated = average lever angle over the past 20 seconds
f) Trouble mode f) Trouble mode
If trouble occurs in the fuel sensor, the bar graph itself is not displayed. If trouble occurs in the fuel sensor, the bar graph itself is not displayed.
If trouble occurs in UART communications, the display is fixed at the last state sent. If trouble occurs in UART communications, the display is fixed at the last state sent.
(Send: Computer A => Monitor) (Send: Computer A => Monitor)
When the trouble is recovered from, the display returns to normal. When the trouble is recovered from, the display returns to normal.
g) Lever angle obtained during trouble g) Lever angle obtained during trouble
If lever angle were obtained and the processing in e) carried out, display upon recovery would not be If lever angle were obtained and the processing in e) carried out, display upon recovery would not be
normal. normal.
In order to prevent this, the lever angle is not obtained during a fuel sensor trouble. In order to prevent this, the lever angle is not obtained during a fuel sensor trouble.

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4001-40 4001-40
Accessories Accessories
1. Horn 1. Horn
Basic operation Basic operation
a) When the horn switch is pressed, the horn is driven via a relay. a) When the horn switch is pressed, the horn is driven via a relay.
b) When the volume select switch is switched ON, the LED indicator lights up and only the left horn sounds (Horn b) When the volume select switch is switched ON, the LED indicator lights up and only the left horn sounds (Horn
volume down). volume down).
The volume select switch state is retained even when the key is switched OFF (The previous data is held). The volume select switch state is retained even when the key is switched OFF (The previous data is held).
c) Communications with computer c) Communications with computer
When this switch is pressed, the signal is first sent to the computer and processed. When this switch is pressed, the signal is first sent to the computer and processed.
Then, the drive command is sent to the monitor and the monitor drives the right horn (R) relay. Then, the drive command is sent to the monitor and the monitor drives the right horn (R) relay.
d) Trouble mode d) Trouble mode
If there is an error in UART communications, the monitor goes into trouble mode. If there is an error in UART communications, the monitor goes into trouble mode.
In trouble mode, the monitor carries out the operation in b) on its own without receiving commands from the In trouble mode, the monitor carries out the operation in b) on its own without receiving commands from the
computer. computer.
However, the previous data is not held (The monitor always starts up with normal volume). However, the previous data is not held (The monitor always starts up with normal volume).
When the error is recovered from, trouble mode ends too and the monitor returns to normal mode When the error is recovered from, trouble mode ends too and the monitor returns to normal mode
z z

Switch signal Drive Switch signal Drive


command command

1 Monitor panel 6 Horn (L) relay 1 Monitor panel 6 Horn (L) relay
2 Horn volume select switch (with led indicator) 7 Horn (R) relay 2 Horn volume select switch (with led indicator) 7 Horn (R) relay
3 Horn switch 8 Horn (R) 3 Horn switch 8 Horn (R)
4 Computer A 9 Horn (L) 4 Computer A 9 Horn (L)
5 Key switch 5 Key switch

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4001-41 4001-41

2. Working Light 2. Working Light


Basic operation Basic operation
a) When turning the key to ON, always start with the working light OFF (Previous data reset). a) When turning the key to ON, always start with the working light OFF (Previous data reset).
b) Each time the working light switch is pressed, the working light is switched between ON and OFF (Momentary). b) Each time the working light switch is pressed, the working light is switched between ON and OFF (Momentary).
When this light is ON, the LED indicator lights up. When this light is ON, the LED indicator lights up.
c) Communications with computer c) Communications with computer
When the working light switch is pressed, the signal is first sent to the computer and processed. When the working light switch is pressed, the signal is first sent to the computer and processed.
Then, the light command is sent to the monitor and the monitor drives the relay. Then, the light command is sent to the monitor and the monitor drives the relay.
d) Trouble mode d) Trouble mode
If there is an abnormality occurs in UART communications, the monitor goes into trouble mode. If there is an abnormality occurs in UART communications, the monitor goes into trouble mode.
In trouble mode, the monitor carries out the operation in b) on its own rather than commands from the In trouble mode, the monitor carries out the operation in b) on its own rather than commands from the
computer. computer.
When the communications error is recovered from, trouble mode is exited and the monitor returns to When the communications error is recovered from, trouble mode is exited and the monitor returns to
normal mode. normal mode.

See See
«Air Conditioner» «Air Conditioner»

Switch Light Switch Light


signal command signal command

For expansion For expansion

1 Monitor panel 6 Working light relay (cab) 1 Monitor panel 6 Working light relay (cab)
2 Working light switch (with LED indicator) 7 Working light (boom) 2 Working light switch (with LED indicator) 7 Working light (boom)
3 Computer A 8 Working light (tool etc.) 3 Computer A 8 Working light (tool etc.)
4 Key switch 9 Working light (cab top) 4 Key switch 9 Working light (cab top)
5 Working light relay (upper) 5 Working light relay (upper)

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


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3. Wiper & Washer 3. Wiper & Washer


a) Configuration a) Configuration

LED LED

WIPER (INT) WIPER (INT)


OPEN OPEN
WIPER (CNT) WIPER (CNT)
OPEN OPEN

WASHER WASHER

Switch signal Drive command Switch signal Drive command

1 Monitor panel 6 Computer A 1 Monitor panel 6 Computer A


2 Washer switch 7 Key switch 2 Washer switch 7 Key switch
3 Wiper switch (with LED indicator) 8 Wiper motor 3 Wiper switch (with LED indicator) 8 Wiper motor
4 Monitor 9 Washer motor 4 Monitor 9 Washer motor
5 Front window limit SW 5 Front window limit SW

b) Wiper basic operation b) Wiper basic operation


When the wiper switch is pressed, it switches to the next state in the order: intermittent operation => When the wiper switch is pressed, it switches to the next state in the order: intermittent operation =>
continuous operation => OFF => intermittent. In intermittent operation, the I LED is lit and in continuous continuous operation => OFF => intermittent. In intermittent operation, the I LED is lit and in continuous
operation, the II LED lights up (When the wipers are OFF, both are OFF). When turning the key ON, always operation, the II LED lights up (When the wipers are OFF, both are OFF). When turning the key ON, always
start from OFF (Previous data reset). start from OFF (Previous data reset).
c) Washer basic operation c) Washer basic operation
While the washer is pressed, the washer operates. While the washer is pressed, the washer operates.
d) Wipers linked with washer d) Wipers linked with washer
While the washer switch is pressed, after 0.5 second, the washer starts to operate linked with the wipers. While the washer switch is pressed, after 0.5 second, the washer starts to operate linked with the wipers.
When the washer switch is released, the washer stops, and after two wipes, the wipers stop too. When the washer switch is released, the washer stops, and after two wipes, the wipers stop too.
1. Auto rise up 1. Auto rise up
Even during wiper operation, if the key is turned OFF, the wipers are automatically stopped and Even during wiper operation, if the key is turned OFF, the wipers are automatically stopped and
retracted. retracted.
2. Overload prevention 2. Overload prevention
If the blades are locked, the monitor output is stopped. If the blades are locked, the monitor output is stopped.

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e) Front window open detection e) Front window open detection
If the front window is opened while the wipers or washer are operating, it is stopped. If the front window is opened while the wipers or washer are operating, it is stopped.
The operations of b) and c) are not carried out while the front window is open. The operations of b) and c) are not carried out while the front window is open.
f) Wiper computer duty f) Wiper computer duty
The wiper computer is responsible for b) - d). e) is provided by the monitor / computer detecting the front The wiper computer is responsible for b) - d). e) is provided by the monitor / computer detecting the front
window being opened and the output to the wiper computer being switched OFF. window being opened and the output to the wiper computer being switched OFF.
g) Computer A duty g) Computer A duty
Computer A receives switch signals from the monitor through UART communications (wiper switch, washer Computer A receives switch signals from the monitor through UART communications (wiper switch, washer
switch, front window limit switch). switch, front window limit switch).
This signal is processed by computer A and the three ports that control the wiper computer (WIPER (INT), This signal is processed by computer A and the three ports that control the wiper computer (WIPER (INT),
WIPER (CNT), and WASHER) are controlled as in the following time chart. WIPER (CNT), and WASHER) are controlled as in the following time chart.
h) Time chart h) Time chart

0.5 second Double wipe 0.5 second Double wipe


0.5 second 0.5 second
Double wipe Double wipe

Wiper operation Wiper operation


mode mode

Operation Wiper LED Operation Wiper LED

Washer Washer

WIPER (INT) WIPER (INT)

Connection Connection
to wiper WIPER (CNT) to wiper WIPER (CNT)
controller controller

WASHER WASHER

Wiper switch Wiper switch

Input Washer switch Input Washer switch

Front window Front window


limit switch limit switch

2) 2) 2) 2)
1. During washer operation, wiper operations are handled automatically by the wiper controler even if there 1. During washer operation, wiper operations are handled automatically by the wiper controler even if there
is no output to WIPER (INT) or WIPER (CNT). is no output to WIPER (INT) or WIPER (CNT).
2. Wiper stop by front window open detection 2. Wiper stop by front window open detection
3. Washer-linked wiper stop by front window open detection 3. Washer-linked wiper stop by front window open detection
i) Trouble mode i) Trouble mode
If there is an error in UART communications, the monitor cannot receive drive commands from computer A. If there is an error in UART communications, the monitor cannot receive drive commands from computer A.
At this time, the monitor goes into trouble mode and executes the same control as for on its own as in h). At this time, the monitor goes into trouble mode and executes the same control as for on its own as in h).
When the UART communications error is recovered from, the monitor recovers from trouble mode and When the UART communications error is recovered from, the monitor recovers from trouble mode and
follows the drive commands from computer A. follows the drive commands from computer A.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-44 4001-44
4. Room Lamp 4. Room Lamp
a) Configuration a) Configuration

OPEN OPEN

CLOSE CLOSE

DOOR DOOR

See «Air See «Air


Conditioner» Conditioner»

1 Key switch 4 Room lamp 1 Key switch 4 Room lamp


2 Clock unit 5 Door limit switch 2 Clock unit 5 Door limit switch
3 Room lamp relay 3 Room lamp relay

• The clock unit is not connected with computer A or B and controls the room lamp relay on its own. • The clock unit is not connected with computer A or B and controls the room lamp relay on its own.
• For the (B) connection destination, see "Air Conditioner". • For the (B) connection destination, see "Air Conditioner".
• The clock unit is connected to the backup power supply and continues to operate even if the key is • The clock unit is connected to the backup power supply and continues to operate even if the key is
switched OFF. switched OFF.
b) Door link b) Door link
When the room lamp switch is set to the DOOR position, the lamp lights when the door is open and goes When the room lamp switch is set to the DOOR position, the lamp lights when the door is open and goes
out when the door is closed. out when the door is closed.
c) Auto lamp off c) Auto lamp off
In b), in order to prevent the battery from being run down, the room lamp goes out 30 seconds after the In b), in order to prevent the battery from being run down, the room lamp goes out 30 seconds after the
door is opened. However, this function only works when the key switch is OFF. If it is ACC or ON, auto lamp door is opened. However, this function only works when the key switch is OFF. If it is ACC or ON, auto lamp
off does not work (Because even if the room lamp relay is OFF, power is supplied from ACC). off does not work (Because even if the room lamp relay is OFF, power is supplied from ACC).
The only purpose of this auto lamp off function is to prevent the battery from being run down if the door is The only purpose of this auto lamp off function is to prevent the battery from being run down if the door is
left open with the key OFF. left open with the key OFF.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-45 4001-45
d) Time chart d) Time chart
The time chart shows how the function in c) works. The room lamp switch is set to DOOR. The time chart shows how the function in c) works. The room lamp switch is set to DOOR.

30 seconds 30 seconds
30 seconds 30 seconds 30 seconds 30 seconds 30 seconds 30 seconds 30 seconds 30 seconds

Room lamp Room lamp

Room lamp Room lamp


relay relay

Door limit Door limit


switch switch

Key switch Key switch

1. Door linked room lamp 1. Door linked room lamp


2. Even after the door is closed, the room lamp relay is ON for 30 seconds. 2. Even after the door is closed, the room lamp relay is ON for 30 seconds.
3. 30 seconds is counted from the last time the door was closed. 3. 30 seconds is counted from the last time the door was closed.
4. After 30 seconds, the lamp goes off automatically. 4. After 30 seconds, the lamp goes off automatically.
5. Auto lamp off does not work if the key switch is ON or ACC. 5. Auto lamp off does not work if the key switch is ON or ACC.
6. When the key is switched OFF, the lamp goes out (After power-cut delay). 6. When the key is switched OFF, the lamp goes out (After power-cut delay).
e) Trouble mode e) Trouble mode
Since the clock unit does not have a trouble detection function for either input (IN1) or output (OUT1), it Since the clock unit does not have a trouble detection function for either input (IN1) or output (OUT1), it
does not go into trouble mode. does not go into trouble mode.
f) Time chart f) Time chart
This shows the operation when the room lamp switch is ON. This shows the operation when the room lamp switch is ON.

30 30 30 30 30 30
seconds seconds seconds seconds seconds seconds

Room lamp Room lamp

Room lamp relay Room lamp relay

Door limit switch Door limit switch


ON = OPEN ON = OPEN
OFF = CLOSED OFF = CLOSED

Key switch Key switch

1. If the key is OFF, the lamp goes out automatically after 30 seconds 1. If the key is OFF, the lamp goes out automatically after 30 seconds
2. Auto lamp off does not work if the key switch is ON or ACC. 2. Auto lamp off does not work if the key switch is ON or ACC.
3. Power-cut delay 3. Power-cut delay

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-46 4001-46

5. Radio Mute 5. Radio Mute


a) Configuration a) Configuration

1 Mute switch (knob) 5 Speaker (R) relay 1 Mute switch (knob) 5 Speaker (R) relay
2 Clock unit 6 Speaker (L) 2 Clock unit 6 Speaker (L)
3 Radio 7 Speaker (R) 3 Radio 7 Speaker (R)
4 Speaker (L) relay 4 Speaker (L) relay

b) Summary and purpose b) Summary and purpose


The radio volume can be switched ON / OFF with one-touch by switching the speaker (L, R) signal lines on The radio volume can be switched ON / OFF with one-touch by switching the speaker (L, R) signal lines on
and off with a relay. and off with a relay.
c) Operation c) Operation
Each time the mute switch on the knob is pressed, the radio volume is switched between ON <=> OFF Each time the mute switch on the knob is pressed, the radio volume is switched between ON <=> OFF
(Momentary). (Momentary).
When the key is switched ON, the radio always starts with mute off (normal radio volume, previous data When the key is switched ON, the radio always starts with mute off (normal radio volume, previous data
reset). reset).
d) Battery save d) Battery save
In order to prevent the battery from being run down, when the key is at ACC (accessory), the radio is In order to prevent the battery from being run down, when the key is at ACC (accessory), the radio is
always set to mute off (normal radio volume). always set to mute off (normal radio volume).
ON ON
Mute Mute
OFF OFF

Speaker (L / R) ON Speaker (L / R) ON
relay relay
OFF OFF

ON ON
Mute switch Mute switch
OFF OFF

ON ON
Key switch ACC Key switch ACC
OFF OFF

Momentary Previous data Battery save Previous data Momentary Previous data Battery save Previous data
reset reset reset reset

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-47 4001-47
Others Others
1. Anti-Theft 1. Anti-Theft
a) Anti-theft setting and password registration and cleaning. a) Anti-theft setting and password registration and cleaning.
For details, see the «service support operation procedure». For details, see the «service support operation procedure».
b) Anti-theft control b) Anti-theft control
If the anti-theft password does not match (anti-theft is not ended), the machine operation is controlled. If the anti-theft password does not match (anti-theft is not ended), the machine operation is controlled.

1 Computer A 5 Travel pressure sensor 1 Computer A 5 Travel pressure sensor


2 Engine 6 Upper pressure sensor 2 Engine 6 Upper pressure sensor
3 P1 pressure sensor 7 Swing brake solenoid 3 P1 pressure sensor 7 Swing brake solenoid
4 P2 pressure sensor 8 Travel alarm 4 P2 pressure sensor 8 Travel alarm

1. If the engine is started without ending the anti-theft, the machine is controlled as follows: 1. If the engine is started without ending the anti-theft, the machine is controlled as follows:
1. The engine speed is fixed at low idle. 1. The engine speed is fixed at low idle.
2. The swing brake cannot be released (Solenoid operation is not possible). 2. The swing brake cannot be released (Solenoid operation is not possible).
3. The travel alarm buzzes continuously. 3. The travel alarm buzzes continuously.
2. In the state in 1., if any of the following operations is executed, the engine is forced to stop. 2. In the state in 1., if any of the following operations is executed, the engine is forced to stop.
1. Upper or travel operation (Detected by the corresponding sensor) 1. Upper or travel operation (Detected by the corresponding sensor)
2. The P1 or P2 pressure rises to 5 MPa (50 bar / 725 psi) or higher. 2. The P1 or P2 pressure rises to 5 MPa (50 bar / 725 psi) or higher.
3. The engine load is 50% or higher for two seconds cumulative. 3. The engine load is 50% or higher for two seconds cumulative.
4. The upper, travel, P1, or P2 pressure sensor is removed. 4. The upper, travel, P1, or P2 pressure sensor is removed.
3. Even in the state in 1., the anti-theft control can be ended by inputting the correct password. 3. Even in the state in 1., the anti-theft control can be ended by inputting the correct password.

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4001-48 4001-48

2. Battery Save Function 2. Battery Save Function


a) Summary and purpose a) Summary and purpose
In order to prevent the battery from being run down when the key is ON and the engine is stopped, solenoid In order to prevent the battery from being run down when the key is ON and the engine is stopped, solenoid
and proportional valve output is suppressed. and proportional valve output is suppressed.
b) Operation b) Operation
See the table below. See the table below.

Control targets Operation when the engine is stopped with the key ON. Control targets Operation when the engine is stopped with the key ON.
Travel high-speed Fixed to OFF (low-speed) whether the travel speed select switch ON or OFF Travel high-speed Fixed to OFF (low-speed) whether the travel speed select switch ON or OFF
switchover solenoid However, the LED at the side of the switch is linked with the switch. switchover solenoid However, the LED at the side of the switch is linked with the switch.
Power save solenoid Fixed to OFF (power save OFF) Power save solenoid Fixed to OFF (power save OFF)
Fixed to OFF (free swing OFF) whether the free swing switch ON or OFF Fixed to OFF (free swing OFF) whether the free swing switch ON or OFF
Free swing solenoid Free swing solenoid
However, the free swing icon on the monitor is linked with the switch. However, the free swing icon on the monitor is linked with the switch.
Fixed to OFF (crusher side) whether the breaker / crusher mode switch ON or Fixed to OFF (crusher side) whether the breaker / crusher mode switch ON or
Option return line Option return line
OFF OFF
switchover solenoid switchover solenoid
However, the attachment icon on the monitor is linked with the switch. However, the attachment icon on the monitor is linked with the switch.
Fixed to OFF (no boost) regardless of the work mode (throttle volume position) Fixed to OFF (no boost) regardless of the work mode (throttle volume position)
Boost solenoid Boost solenoid
However, the status icon on the monitor is linked with the throttle However, the status icon on the monitor is linked with the throttle
0 mA, so the standby milli-amp for detecting disconnections of 50 mA does not 0 mA, so the standby milli-amp for detecting disconnections of 50 mA does not
Pump horsepower Pump horsepower
flow flow
proportional valve proportional valve
Disconnections are only detected after the engine has started Disconnections are only detected after the engine has started
Pump flow Same as above Pump flow Same as above
proportional valve proportional valve

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-49 4001-49

3. Alternator Power Generation Detection 3. Alternator Power Generation Detection


a) Configuration (fuses etc. omitted) a) Configuration (fuses etc. omitted)

10 V Comparator 10 V Comparator
To load To load

B: Charge B: Charge
L: Running signal L: Running signal
R: Initial excitation R: Initial excitation
E: GND E: GND

1 Computer A 3 Battery relay 1 Computer A 3 Battery relay


2 Key switch 4 Alternator 2 Key switch 4 Alternator

b) Separated from battery voltage b) Separated from battery voltage


When the battery relay is closed, by looking not at the B terminal, where the battery voltage is applied, but When the battery relay is closed, by looking not at the B terminal, where the battery voltage is applied, but
rather to the independent L terminal, defects in the alternator alone are detected (The battery voltage is rather to the independent L terminal, defects in the alternator alone are detected (The battery voltage is
monitored by the ECM (IN2)). monitored by the ECM (IN2)).
c) Operation c) Operation
Alternator L terminal output voltage judged with 10V comparator Alternator L terminal output voltage judged with 10V comparator
ON when L terminal voltage ≥ 10 V ON when L terminal voltage ≥ 10 V
OFF when L terminal voltage < 10 V. * The threshold value of 10 V has a tolerance of ±1 V. OFF when L terminal voltage < 10 V. * The threshold value of 10 V has a tolerance of ±1 V.
d) Power generation defect judgment d) Power generation defect judgment
If the 10V comparator input is OFF even though the engine is running, it is judged that there is a power If the 10V comparator input is OFF even though the engine is running, it is judged that there is a power
generation defect. For details on the judgment conditions, see the "Main Unit Diagnostic Trouble Code generation defect. For details on the judgment conditions, see the "Main Unit Diagnostic Trouble Code
List". List".

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-50 4001-50

4. Overload Alarm (Europe only) 4. Overload Alarm (Europe only)


a) Configuration a) Configuration

Buzzer, message Buzzer, message

1 Overload alarm switch (alternate) 4 Boom cylinder bottom pressure sensor 1 Overload alarm switch (alternate) 4 Boom cylinder bottom pressure sensor
2 Monitor panel 5 Boom 2 Monitor panel 5 Boom
3 Computer A 6 Boom cylinder 3 Computer A 6 Boom cylinder

b) Alarm judgment b) Alarm judgment


When the overload alarm switch is ON, the overload alarm is switched ON / OFF according to the following When the overload alarm switch is ON, the overload alarm is switched ON / OFF according to the following
conditions. conditions.
ON: (Boom cylinder bottom pressure ≥ set pressure) for 1 continuous second ON: (Boom cylinder bottom pressure ≥ set pressure) for 1 continuous second
OFF: (Boom cylinder bottom pressure ≤ set pressure - 2 MPa (- 20 bar / - 290 psi)) continuous for 1 second OFF: (Boom cylinder bottom pressure ≤ set pressure - 2 MPa (- 20 bar / - 290 psi)) continuous for 1 second
• For the set pressure for each model, see "Overload set pressure". • For the set pressure for each model, see "Overload set pressure".
• The set pressure can be changed with CFG (see the "Service Support" chapter). • The set pressure can be changed with CFG (see the "Service Support" chapter).
c) Operation when alarm judgment ON c) Operation when alarm judgment ON
The "OVER LOAD" message is displayed on the monitor and the buzzer buzzes intermittently. The "OVER LOAD" message is displayed on the monitor and the buzzer buzzes intermittently.
This message is handled as an "alert". For details, see "Message Display List". This message is handled as an "alert". For details, see "Message Display List".
d) Ending the alarm d) Ending the alarm
To end an alarm that has been issued, either switch the overload alarm switch OFF or operate the To end an alarm that has been issued, either switch the overload alarm switch OFF or operate the
attachment in such a way that the judgment in b) goes OFF. attachment in such a way that the judgment in b) goes OFF.
Note that there is no buzzer stop switch. Note that there is no buzzer stop switch.
e) Trouble mode e) Trouble mode
If trouble occurs in the boom cylinder bottom pressure sensor, this function goes into trouble mode and the If trouble occurs in the boom cylinder bottom pressure sensor, this function goes into trouble mode and the
alarm judgment is fixed to OFF. alarm judgment is fixed to OFF.
Even if the trouble is recovered from, trouble mode continues until the key is switched OFF. Even if the trouble is recovered from, trouble mode continues until the key is switched OFF.
f) Trouble judgment f) Trouble judgment
The boom cylinder bottom pressure sensor trouble judgment is made after the overload alarm switch has The boom cylinder bottom pressure sensor trouble judgment is made after the overload alarm switch has
come ON once. come ON once.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-51 4001-51
g) Time chart g) Time chart

1 second 1 second 1 second 1 second 1 second 1 second 1 second 1 second 1 second 1 second

ON ON
Message Message
OFF OFF

ON ON
Monitor buzzer Monitor buzzer
OFF OFF

ON ON
Alarm judgment Alarm judgment
OFF OFF

Boom cylinder Set pressure Boom cylinder Set pressure


bottom pressure bottom pressure
Set pressure Set pressure
- 2 MPa - 2 MPa

Overload alarm ON Overload alarm ON


switch switch
OFF OFF

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-52 4001-52
Options Options
1. Option Line Control 1. Option Line Control
a) Configuration [Multi purpose circuit with 2nd option line] a) Configuration [Multi purpose circuit with 2nd option line]

Crusher Crusher

Rotation Rotation

Center OR Center OR
bypass bypass
cut cut

OPTION 1 OPTION 1

(Pedal type) (Pedal type)

The hydraulic pressure The hydraulic pressure


source is different. source is different.

The ground The ground


treatment is treatment is
different. different.

(Knob switch type) (Knob switch type)

1 Monitor panel 10 Shut-off valve 1 Monitor panel 10 Shut-off valve


2 Breaker mode switch 11 2 pumps flow solenoid valve 2 Breaker mode switch 11 2 pumps flow solenoid valve
3 Option select switch 12 Option switchover solenoid valve 3 Option select switch 12 Option switchover solenoid valve
4 Crusher mode switch 13 1st option pedal 4 Crusher mode switch 13 1st option pedal
5 2 pumps flow switch 14 1st option pressure switch 5 2 pumps flow switch 14 1st option pressure switch
6 2nd option control valve 15 1st option switch (L) 6 2nd option control valve 15 1st option switch (L)
7 4th pump 16 1st option switch (R) 7 4th pump 16 1st option switch (R)
8 Control valve 17 Computer A 8 Control valve 17 Computer A
9 3-direction valve 9 3-direction valve

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-53 4001-53
Option select switch switchover (breaker mode <=> crusher mode) Option select switch switchover (breaker mode <=> crusher mode)
Operation: Operation:
When the option select switch is set to the breaker mode switch side, the option switchover solenoid valve When the option select switch is set to the breaker mode switch side, the option switchover solenoid valve
is operated and the shut-off valve is switched to the 3-direction valve. When the switch is switched to is operated and the shut-off valve is switched to the 3-direction valve. When the switch is switched to
crusher mode, the option switchover solenoid valve goes OFF. crusher mode, the option switchover solenoid valve goes OFF.

Option 2 Option 2

(Pedal type) (Pedal type)

(Knob switch type) (Knob switch type)

1 2nd option pedal 1 2nd option pedal


2 2nd option switch (L) 2 2nd option switch (L)
3 2nd option switch (R) 3 2nd option switch (R)

2 pumps flow select switch (1 pump <=> 2pumps) 2 pumps flow select switch (1 pump <=> 2pumps)
Operation: Operation:
When the 2 pumps flow switch is switched ON, the solenoid valve for 2 pumps flow to 2 pumps flow. When the 2 pumps flow switch is switched ON, the solenoid valve for 2 pumps flow to 2 pumps flow.
Difference between pedal type and knob switch type Difference between pedal type and knob switch type
For the pedal type, solenoid valve for 2 pumps flow hydraulic pressure source is the secondary pressure For the pedal type, solenoid valve for 2 pumps flow hydraulic pressure source is the secondary pressure
via the option 1 pedal shuttle, but for the knob switch type, the solenoid for the 2 pumps flow pressure via the option 1 pedal shuttle, but for the knob switch type, the solenoid for the 2 pumps flow pressure
source comes directly from the gear pump. source comes directly from the gear pump.
Therefore, when the 2 pumps flow switch is switched ON, operation becomes always 2 pumps flow. Therefore, when the 2 pumps flow switch is switched ON, operation becomes always 2 pumps flow.
In order to prevent this, whereas for the pedal type the ground treatment for the 2 pumps flow switch is to In order to prevent this, whereas for the pedal type the ground treatment for the 2 pumps flow switch is to
ground directly, with the knob switch type, it is set so that the switch is not grounded unless one or the other ground directly, with the knob switch type, it is set so that the switch is not grounded unless one or the other
of the option switches is ON. of the option switches is ON.
• Be careful. The shuttle valve is built into the option 1 pedal remote control valve. • Be careful. The shuttle valve is built into the option 1 pedal remote control valve.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-54 4001-54
Mode select switch Mode select switch
When the breaker mode switch / crusher mode switch is pressed, the option line mode changes as follows. When the breaker mode switch / crusher mode switch is pressed, the option line mode changes as follows.

Breaker 1 Breaker 2 Breaker 5 Breaker 1 Breaker 2 Breaker 5


mode mode mode mode mode mode
Breaker 1 Breaker 1
mode mode

Normal dig Normal dig Normal dig Normal dig

Crusher 1 Crusher 1
mode mode
Crusher 1 Crusher 2 Crusher 5 Crusher 1 Crusher 2 Crusher 5
mode mode mode mode mode mode

• The factory setting is that only breaker 1 mode and crusher 1 mode can be selected. • The factory setting is that only breaker 1 mode and crusher 1 mode can be selected.
• With settings on the service screen, the number of modes can be increased to five each for the breaker • With settings on the service screen, the number of modes can be increased to five each for the breaker
and for the crusher, for a total of 10. and for the crusher, for a total of 10.
b) For a), the following icons are displayed according to the mode. b) For a), the following icons are displayed according to the mode.

Breaker mode Crusher mode Normal dig mode Breaker mode Crusher mode Normal dig mode

None None

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-55 4001-55

2. Option Line Control 2. Option Line Control


a) Configuration [Multipurpose circuit with 2nd option line (pedal type)] a) Configuration [Multipurpose circuit with 2nd option line (pedal type)]

There are two operation methods: the pedal type and the knob switch There are two operation methods: the pedal type and the knob switch
type. With either type, when the pedal or knob switch is operated the type. With either type, when the pedal or knob switch is operated the
switch input port (IN3, IN4 = «option select and operating method» IN4, switch input port (IN3, IN4 = «option select and operating method» IN4,
IN5) is the same. (In other words, there is no need to be aware of the IN5) is the same. (In other words, there is no need to be aware of the
difference in operating method). difference in operating method).

The explanation below uses the pedal method. The explanation below uses the pedal method.

1 Computer A 12 Straight travel 1 Computer A 12 Straight travel


2 N2 pressure sensor 13 Swing pressure sensor 2 N2 pressure sensor 13 Swing pressure sensor
3 Arm (1) 14 Travel pressure sensor 3 Arm (1) 14 Travel pressure sensor
4 Option 15 Option pedal 4 Option 15 Option pedal
5 Boom (2) 16 Option pressure switch 5 Boom (2) 16 Option pressure switch
6 Swing 17 2nd option pedal 6 Swing 17 2nd option pedal
7 Travel (left) 18 2nd option pressure switch 7 Travel (left) 18 2nd option pressure switch
8 Arm (2) 19 Boost solenoid 8 Arm (2) 19 Boost solenoid
9 Bucket 20 P1 pump 9 Bucket 20 P1 pump
10 Boom (1) 21 P2 pump 10 Boom (1) 21 P2 pump
11 Travel (right) 22 P1 flow control proportional valve 11 Travel (right) 22 P1 flow control proportional valve

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-56 4001-56
b) Option line operation control b) Option line operation control
The table below shows the control for operation of the single option and compound operation. The table below shows the control for operation of the single option and compound operation.

Option line mode Breaker Crusher Option 2 Option line mode Breaker Crusher Option 2
1st option pressure 1st option pressure 2nd option pressure 1st option pressure 1st option pressure 2nd option pressure
switch => ON switch => ON switch => ON switch => ON switch => ON switch => ON
Operation Operation
(IN3 is ground) (IN3 is ground) (IN4 is ground) (IN3 is ground) (IN3 is ground) (IN4 is ground)
Single Compound Single Compound Single Compound Single Compound Single Compound Single Compound
Boost cut Yes Yes No Boost cut Yes Yes No
Flow restriction Yes Yes No No function (4th pump) Flow restriction Yes Yes No No function (4th pump)
Engine speed / Engine speed /
Pump horsepower According to the command for the work mode selected with the throttle Pump horsepower According to the command for the work mode selected with the throttle
milli-amp milli-amp

• The flow is not cut for compound crusher operation (To secure speed for compound operation). • The flow is not cut for compound crusher operation (To secure speed for compound operation).
• Since the breaker often works while the machine is jacked up with the boom (compound operation), the • Since the breaker often works while the machine is jacked up with the boom (compound operation), the
flow is cut even for compound work (The same as the engine reduction for the current breaker). flow is cut even for compound work (The same as the engine reduction for the current breaker).
• The pressure boost is cut when Option 1 and Option 2 are operated at the same time (Boost cut • The pressure boost is cut when Option 1 and Option 2 are operated at the same time (Boost cut
priority). priority).
• The engine speed and pump horsepower milli-amp are according to the work mode currently selected • The engine speed and pump horsepower milli-amp are according to the work mode currently selected
with the throttle (cannot be forced to change to another mode only for breaker/crusher). with the throttle (cannot be forced to change to another mode only for breaker/crusher).
c) Option 1 single operation judgment conditions c) Option 1 single operation judgment conditions
When all the conditions below are satisfied, it is judged that this is single operation. When all the conditions below are satisfied, it is judged that this is single operation.
Conditions: Conditions:

1st option pressure switch => ON Swing pressure sensor => OFF 1st option pressure switch => ON Swing pressure sensor => OFF
Travel pressure sensor => OFF N2 pressure sensor ≥ 2.4 MPa (24 bar / 348 psi) Travel pressure sensor => OFF N2 pressure sensor ≥ 2.4 MPa (24 bar / 348 psi)

d) Flow cut d) Flow cut


The maximum flow for option line operation is restricted to the flow for the option line mode selected with The maximum flow for option line operation is restricted to the flow for the option line mode selected with
"Option line selection and 2 pumps flow". "Option line selection and 2 pumps flow".
Also, be careful about the fact that since the flow set for the option line is the flow for SP mode, when used Also, be careful about the fact that since the flow set for the option line is the flow for SP mode, when used
in H/A mode, the flow is slightly less than the display. in H/A mode, the flow is slightly less than the display.
When neither the braker or crusher mode is selected (normal mode), the minimum flow amount 50L/min When neither the braker or crusher mode is selected (normal mode), the minimum flow amount 50L/min
(13.2 gpm) is produced when the pedal is pressed. (For prevention of damage to attachments) (13.2 gpm) is produced when the pedal is pressed. (For prevention of damage to attachments)
e) Trouble mode e) Trouble mode
If a trouble occurs in input (swing pressure sensor, travel pressure sensor, N2 pressure sensor) or output If a trouble occurs in input (swing pressure sensor, travel pressure sensor, N2 pressure sensor) or output
(boost solenoid, flow proportional valve), the machine goes into trouble mode and (boost solenoid, flow proportional valve), the machine goes into trouble mode and
• Output command to boost solenoid = fixed to OFF • Output command to boost solenoid = fixed to OFF
• Output command to flow proportional valve = fixed to OFF • Output command to flow proportional valve = fixed to OFF
Trouble mode continues until the key is switched OFF. Trouble mode continues until the key is switched OFF.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-57 4001-57
3. Feed Pump Automatic Stop 3. Feed Pump Automatic Stop
a) Configuration a) Configuration

Full Full
100% 100%

Empty Empty
0% 0%

The accessory switch is fixed ON. The accessory switch is fixed ON.

Manual Manual
(momentary) (momentary)

Automatic Automatic
(alternate) (alternate)

When ON, auto feed is disabled. When ON, auto feed is disabled.
When OFF, auto feed is enabled. When OFF, auto feed is enabled.
Actual speed Actual speed

1 Computer A 6 Oil feed pump 1 Computer A 6 Oil feed pump


2 Feed switch 7 Feed stop relay 2 Feed switch 7 Feed stop relay
3 Fuel sensor 8 Full tank detection buzzer 3 Fuel sensor 8 Full tank detection buzzer
4 Fuel tank 9 Engine 4 Fuel tank 9 Engine
5 Oil feed start relay 5 Oil feed start relay

Feed pump main unit accessory (original) switch. This must be fixed ON beforehand in order to use this Feed pump main unit accessory (original) switch. This must be fixed ON beforehand in order to use this
function. function.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-58 4001-58
b) Operating method b) Operating method
1. With the engine stopped and the key ON, if the feed switch is flipped down to the Auto side, the fuel feed 1. With the engine stopped and the key ON, if the feed switch is flipped down to the Auto side, the fuel feed
starts. starts.
2. When the tank is full, the fuel feed stops automatically and the buzzer buzzes to announce that. 2. When the tank is full, the fuel feed stops automatically and the buzzer buzzes to announce that.
3. Returning the feed switch to the center stops the buzzer. 3. Returning the feed switch to the center stops the buzzer.
4. To feed more fuel 4. To feed more fuel
Press the feed switch manual side. The fuel is fed while the switch is pressed. Press the feed switch manual side. The fuel is fed while the switch is pressed.
c) Computer control targets c) Computer control targets
Input = Fuel sensor (0 to 100%), engine state (running / stopped) Input = Fuel sensor (0 to 100%), engine state (running / stopped)
Output = Feed stop relay Output = Feed stop relay
d) System state (when relay OFF) d) System state (when relay OFF)
When the feed switch is set to the Auto side, the start relay comes ON and the pump operates. When the feed switch is set to the Auto side, the start relay comes ON and the pump operates.
e) System state (when relay ON) e) System state (when relay ON)
When the feed switch is set to the Auto side, the start relay goes OFF, and the pump does not operate. When the feed switch is set to the Auto side, the start relay goes OFF, and the pump does not operate.
Also, the buzzer buzzes. Also, the buzzer buzzes.
f) Feed stop relay control (while engine stopped and key ON) f) Feed stop relay control (while engine stopped and key ON)
When (fuel level < 94% continuously for 3 seconds), OFF (auto feed enabled) When (fuel level < 94% continuously for 3 seconds), OFF (auto feed enabled)
When (fuel level ≥ 94% continuously for 3 seconds), ON (auto feed disabled). When (fuel level ≥ 94% continuously for 3 seconds), ON (auto feed disabled).

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g) Time chart g) Time chart

f) f)

3 seconds 3 seconds 3 seconds 3 seconds

Full tank detection Full tank detection


buzzer buzzer

Feed pump Feed pump

Feed relay Feed relay

3 seconds 3 seconds

Feed stop Feed stop


relay relay

Feed switch Feed switch

Fuel level Fuel level

Key switch Key switch

1. Fuel feed is not possible unless the key is switched ON. 1. Fuel feed is not possible unless the key is switched ON.
2. When the operator forgets and leaves the switch switched to the Auto side, the pump operates during 2. When the operator forgets and leaves the switch switched to the Auto side, the pump operates during
the power-cut delay (When fuel level under 98%). the power-cut delay (When fuel level under 98%).
3. Power-cut delay. 3. Power-cut delay.
h) Trouble mode h) Trouble mode
If trouble occurs in an input (fuel sensor), output (feed stop relay) or communication (CAN), the system If trouble occurs in an input (fuel sensor), output (feed stop relay) or communication (CAN), the system
goes into trouble mode and the feed stop relay is fixed to OFF. Be careful. In trouble mode, even if the feed goes into trouble mode and the feed stop relay is fixed to OFF. Be careful. In trouble mode, even if the feed
switch is set to Auto, the fuel feed is not stopped. switch is set to Auto, the fuel feed is not stopped.

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4. Return Filter Clogging Detected 4. Return Filter Clogging Detected


a) Configuration a) Configuration

Return oil Return oil

OFF for a clog OFF for a clog


ON for normal ON for normal

1 Computer A 1 Computer A
2 Return filter clog pressure switch 2 Return filter clog pressure switch
3 Hydraulic oil tank 3 Hydraulic oil tank
4 Return filter 4 Return filter

b) Return filter clog pressure switch specifications b) Return filter clog pressure switch specifications
ON: 0.1 MPa OFF: 0.08 MPa ON: 0.1 MPa OFF: 0.08 MPa
(1 bar / 14.50 psi) (0.8 bar / 11.60psi) (1 bar / 14.50 psi) (0.8 bar / 11.60psi)
ON ON

OFF 0.08 MPa 0.1 MPa


OFF 0.08 MPa 0.1 MPa
(0.8 bar / 11.60 psi) (1bar / 14.50 psi) (0.8 bar / 11.60 psi) (1bar / 14.50 psi)

c) Detection cancellation when breaker used c) Detection cancellation when breaker used
When the breaker is used, the return oil pressure pulse is intense, so clog detection is not attempted. When the breaker is used, the return oil pressure pulse is intense, so clog detection is not attempted.
d) Detection cancellation when oil temperature low d) Detection cancellation when oil temperature low
When the oil temperature is less than 30°C (86°F), its viscosity rises and filter pressure damage increases, When the oil temperature is less than 30°C (86°F), its viscosity rises and filter pressure damage increases,
so clog detection is not attempted. so clog detection is not attempted.

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e) Solution for machines with no breaker setting e) Solution for machines with no breaker setting
Machines with no breaker setting from c) (= machines with no return filter clog pressure switch) Machines with no breaker setting from c) (= machines with no return filter clog pressure switch)
Even with these machines, filter clogs would be detected. In order to prevent this, a special connector is Even with these machines, filter clogs would be detected. In order to prevent this, a special connector is
set that is always shorted. set that is always shorted.
Always-shorted special Always-shorted special
connector connector

1 Computer A 1 Computer A

f) Disconnection detection f) Disconnection detection


When the key is ON, if IN1 was OFF before the engine was star ted, the situation is judged to be a When the key is ON, if IN1 was OFF before the engine was star ted, the situation is judged to be a
disconnection abnormality. disconnection abnormality.

5. Beacon (Europe Only) 5. Beacon (Europe Only)


a) Configuration a) Configuration

Up to here is the Up to here is the


common harness common harness

1 Beacon switch (alternate) 1 Beacon switch (alternate)


2 Computer A 2 Computer A
3 Beacon 3 Beacon

b) Destination b) Destination
This function is for Europe. This function is for Europe.
c) Operation c) Operation
The beacon is driven via the beacon relay linked with the beacon switch. The beacon is driven via the beacon relay linked with the beacon switch.
This function is not mediated by the computer. This function is not mediated by the computer.

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This page has been left blank intentionally This page has been left blank intentionally

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ENGINE SUMMARY ENGINE SUMMARY

1. Engine System Diagram 1. Engine System Diagram

Flow of air and combustion gas Flow of air and combustion gas
Flow of fuel Flow of fuel
1 1
Flow of coolant Flow of coolant

5 5
6 7 6 7

2 3 4 8 12 13 2 3 4 8 12 13
9 9
10 10
11 11

In In

14 14

15 16 17 15 16 17

1. Air cleaner 1. Air cleaner


2. Fuel cooler 2. Fuel cooler
3. Inter cooler 3. Inter cooler
4. Radiator 4. Radiator
5. Turbo 5. Turbo
6. Compressor side 6. Compressor side
7. Turbine side 7. Turbine side
8. Engine 8. Engine
9. Injector 9. Injector
10. Common rail 10. Common rail
11. Supply pump 11. Supply pump
12. EGR cooler 12. EGR cooler
13. Muffler 13. Muffler
14. Fuel main filter 14. Fuel main filter
15. Fuel tank 15. Fuel tank
16. Fuel prefilter 16. Fuel prefilter
17. Charge fuel pump 17. Charge fuel pump

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2. Fuel System Diagram 2. Fuel System Diagram
1) System schematic diagram (4JJ1) 1) System schematic diagram (4JJ1)

8 8
2 9 2 9
11 11
1 1

5 6 5 6

13 3 13 3

4 ECM 4 ECM

12 7 10 12 7 10

TSJJ0102 TSJJ0102

1. Common rail 1. Common rail


2. Fuel filter 2. Fuel filter
3. Injector 3. Injector
4. Fuel tank 4. Fuel tank
5. Pre-filter 5. Pre-filter
6. Supply pump 6. Supply pump
7. CKP sensor 7. CKP sensor
8. Common rail pressure sensor 8. Common rail pressure sensor
9. Pressure limiter 9. Pressure limiter
10. Each sensor 10. Each sensor
11. Electromagnetic pump 11. Electromagnetic pump
12. CMP sensor 12. CMP sensor
13. Fuel cooler 13. Fuel cooler

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3. Detailed Part 3. Detailed Part


1) ECM (Engine Control Module) 1) ECM (Engine Control Module)

Roles of the ECM Roles of the ECM


1. The ECM constantly monitors information sent from the various sensors and controls the power train 1. The ECM constantly monitors information sent from the various sensors and controls the power train
systems. systems.
2. The ECM executes system function diagnosis, detects problems in system operation, issues trouble 2. The ECM executes system function diagnosis, detects problems in system operation, issues trouble
alarms to warn the operator and stores the diagnostic trouble code into memory. alarms to warn the operator and stores the diagnostic trouble code into memory.
The diagnostic trouble code identifies the area in which the problem occurred and supports repair work The diagnostic trouble code identifies the area in which the problem occurred and supports repair work
by the service engineer. by the service engineer.
3. The ECM puts out 5 V and other voltages to supply power to the various sensors and switches. 3. The ECM puts out 5 V and other voltages to supply power to the various sensors and switches.
The ECM controls output circuits by controlling ground or power supply circuits via one device or The ECM controls output circuits by controlling ground or power supply circuits via one device or
another. another.
2) Supply Pump 2) Supply Pump

1. Fuel Temperature sensor 3. Feed Pump 1. Fuel Temperature sensor 3. Feed Pump
2. SCV (Suction Control Valve) 2. SCV (Suction Control Valve)
Supply pump Supply pump
The supply pump uses the force of the engine rotation to raise the fuel pressure and send fuel to the The supply pump uses the force of the engine rotation to raise the fuel pressure and send fuel to the
common rail. The SCV, fuel temperature sensor, and feed pump are installed on the supply pump. common rail. The SCV, fuel temperature sensor, and feed pump are installed on the supply pump.
SCV (suction control valve) SCV (suction control valve)
The SCV is installed on the supply pump and controls the sending of fuel to the common rail (discharge The SCV is installed on the supply pump and controls the sending of fuel to the common rail (discharge
volume). The ECM controls the electrified time to the SCV and controls the fuel discharge volume. volume). The ECM controls the electrified time to the SCV and controls the fuel discharge volume.

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3) Common Rail 3) Common Rail

1. Common rail 1. Common rail


Common rail Common rail
The common rail receives the fuel from the supply pump, holds the common rail (fuel) pressure, and The common rail receives the fuel from the supply pump, holds the common rail (fuel) pressure, and
distributes the fuel to each cylinder. The common rail pressure sensor, flow damper, and pressure limiter distributes the fuel to each cylinder. The common rail pressure sensor, flow damper, and pressure limiter
are installed on the common rail. are installed on the common rail.
4) Common Rail pressure sensor and pressure limiter 4) Common Rail pressure sensor and pressure limiter

1. Common rail pressure sensor 1. Common rail pressure sensor


2. Pressure limiter 2. Pressure limiter
Common rail pressure sensor Common rail pressure sensor
This sensor sends the pressure inside the common rail to the ECM as a voltage signal. From the signal This sensor sends the pressure inside the common rail to the ECM as a voltage signal. From the signal
sent, the ECM calculates the actual common rail pressure (fuel pressure) and uses this for fuel injection sent, the ECM calculates the actual common rail pressure (fuel pressure) and uses this for fuel injection
control. control.
Pressure limiter Pressure limiter
If the pressure in the common rail becomes abnormally high pressure, the pressure limiter relieves the If the pressure in the common rail becomes abnormally high pressure, the pressure limiter relieves the
pressure by returning excess fuel to the tank. pressure by returning excess fuel to the tank.

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5) Injector 5) Injector

The injectors are installed on the cylinder head sections. They are controlled from the ECM and inject The injectors are installed on the cylinder head sections. They are controlled from the ECM and inject
fuel. The injector drive voltage is boosted (to 118 V) inside the ECM and applied to the injectors. By fuel. The injector drive voltage is boosted (to 118 V) inside the ECM and applied to the injectors. By
controlling the injector electrified time, the ECM controls the fuel injection, injection timing, etc. controlling the injector electrified time, the ECM controls the fuel injection, injection timing, etc.
6) Engine coolant temperature sensor 6) Engine coolant temperature sensor

The engine coolant temperature sensor is installed on the engine block. The resistance of its thermistor The engine coolant temperature sensor is installed on the engine block. The resistance of its thermistor
varies with the temperature. varies with the temperature.
The resistance is low when the engine coolant temperature is high and high when the coolant temperature The resistance is low when the engine coolant temperature is high and high when the coolant temperature
is low. From the ECM voltage variation, the ECM calculates the engine coolant temperature and uses this is low. From the ECM voltage variation, the ECM calculates the engine coolant temperature and uses this
for fuel injection control etc. for fuel injection control etc.
7) Engine oil pressure sensor 7) Engine oil pressure sensor

The engine oil pressure sensor is installed near the cylinder block starter motor. It detects the engine The engine oil pressure sensor is installed near the cylinder block starter motor. It detects the engine
oil pressure, converts this pressure into an electrical signal, and sends that signal to the ECM. oil pressure, converts this pressure into an electrical signal, and sends that signal to the ECM.

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8) Cam position sensor (CMP sensor) 8) Cam position sensor (CMP sensor)

This sensor sends a signal to the ECM when the engine camshaft cam section passes this sensor. This sensor sends a signal to the ECM when the engine camshaft cam section passes this sensor.
The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses this The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses this
information to control the fuel injection and to calculate the engine speed. information to control the fuel injection and to calculate the engine speed.
Also, it provides a back-up function in case of trouble in the CKP sensor. However, if there is trouble in the Also, it provides a back-up function in case of trouble in the CKP sensor. However, if there is trouble in the
CMP sensor system, there is no change in the behavior while the engine runs, but after it stops, the engine CMP sensor system, there is no change in the behavior while the engine runs, but after it stops, the engine
cannot start. cannot start.
9) Crank position sensor (CKP sensor) 9) Crank position sensor (CKP sensor)

This sensor sends a signal to the ECM when the projection section of the engine flywheel passes this This sensor sends a signal to the ECM when the projection section of the engine flywheel passes this
sensor. sensor.
The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses this The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses this
information to control the fuel injection and to calculate the engine speed. information to control the fuel injection and to calculate the engine speed.
In case of trouble in the CKP sensor, the CMP sensor provides a back-up function. In case of trouble in the CKP sensor, the CMP sensor provides a back-up function.

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10) Atmospheric pressure sensor 10) Atmospheric pressure sensor

The atmospheric pressure sensor is installed in the cab. The ECM converts the atmospheric pressure into an The atmospheric pressure sensor is installed in the cab. The ECM converts the atmospheric pressure into an
electric signal and calculates the atmospheric pressure from this voltage signal and corrects the fuel injection electric signal and calculates the atmospheric pressure from this voltage signal and corrects the fuel injection
quantity according to the atmospheric pressure. quantity according to the atmospheric pressure.
11) Suction air temperature sensor 11) Suction air temperature sensor

The suction air temperature sensor is installed midway through the suction air duct. It detects the suction The suction air temperature sensor is installed midway through the suction air duct. It detects the suction
air temperature in order to optimize the fuel injection quantity. air temperature in order to optimize the fuel injection quantity.

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12) Boost pressure sensor 12) Boost pressure sensor

The boost pressure sensor uses a pressure hose between the boost pressure sensor and intake pipe to detect The boost pressure sensor uses a pressure hose between the boost pressure sensor and intake pipe to detect
the boost (suction air pressure), converts this pressure into an electrical signal, and sends that signal to the the boost (suction air pressure), converts this pressure into an electrical signal, and sends that signal to the
ECM. ECM.
13) Boost temperature sensor 13) Boost temperature sensor

The boost temperature sensor is installed on the upstream side of the EGR valve on the intake manifold. The boost temperature sensor is installed on the upstream side of the EGR valve on the intake manifold.
This sensor is the thermistor type. The internal resistance of the sensor changes with the temperature. This sensor is the thermistor type. The internal resistance of the sensor changes with the temperature.
14) Charge Fuel Pump 14) Charge Fuel Pump

Converting the fuel filter and pre-filter to remote operation increased the distance from the fuel tank to the Converting the fuel filter and pre-filter to remote operation increased the distance from the fuel tank to the
feed pump. feed pump.
Therefore, this pump was added to assist in drawing the fuel from the tank and to make it easy to bleed out Therefore, this pump was added to assist in drawing the fuel from the tank and to make it easy to bleed out
air during maintenance. air during maintenance.
This pump always operates when the key switch is ON. This pump always operates when the key switch is ON.

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15) EGR Valve 15) EGR Valve

The operation of the EGR valve (lift amount) is controlled by signals from the ECM. The operation of the EGR valve (lift amount) is controlled by signals from the ECM.

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4. Engine Control Summary 4. Engine Control Summary


Electronic control fuel injection system (common rail type) Electronic control fuel injection system (common rail type)
This is a system in which the engine speed, engine load, and other information (signals from many sensors) This is a system in which the engine speed, engine load, and other information (signals from many sensors)
are acquired from the engine control module (ECM) and based on that information, the ECM sends electrical are acquired from the engine control module (ECM) and based on that information, the ECM sends electrical
signals to the supply pump, injectors, etc. to appropriately control the fuel injection quantity and timing for signals to the supply pump, injectors, etc. to appropriately control the fuel injection quantity and timing for
each cylinder. each cylinder.
Injection quantity control Injection quantity control
To provide the optimum injection quantity, the ECM controls the injectors based mainly on the engine speed To provide the optimum injection quantity, the ECM controls the injectors based mainly on the engine speed
and the instructed speed from computer A and controls the fuel injection quantity. and the instructed speed from computer A and controls the fuel injection quantity.
Injection pressure control Injection pressure control
The injection pressure is controlled by controlling the fuel pressure in the common rail. The appropriate The injection pressure is controlled by controlling the fuel pressure in the common rail. The appropriate
pressure in the common rail is calculated from the engine speed and fuel injection quantity and by controlling pressure in the common rail is calculated from the engine speed and fuel injection quantity and by controlling
the supply pump, the appropriate quantity of fuel is discharged and the pressure sent to the common rail is the supply pump, the appropriate quantity of fuel is discharged and the pressure sent to the common rail is
controlled. controlled.
Injection timing control Injection timing control
Instead of a timer function, the injectors are controlled primarily by calculating the appropriate fuel injection Instead of a timer function, the injectors are controlled primarily by calculating the appropriate fuel injection
timing from the engine speed, injection quantity, etc. timing from the engine speed, injection quantity, etc.
Injection ratio control Injection ratio control
In order to improve the combustion in the cylinder, at first only a small amount of fuel is injected (pre- In order to improve the combustion in the cylinder, at first only a small amount of fuel is injected (pre-
injection), the fuel is ignited, then once the fuel has ignited, a second injection (main injection) is carried out. injection), the fuel is ignited, then once the fuel has ignited, a second injection (main injection) is carried out.
This injection timing and quantity control is effected by controlling the injectors. This injection timing and quantity control is effected by controlling the injectors.

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EXPLANATION OF ENGINE FUNCTION EXPLANATION OF ENGINE FUNCTION

1. Engine Function Explanation table 1. Engine Function Explanation table

Name Function Name Function


Receives the high-pressure fuel sent under pressure from the supply pump, holds the Receives the high-pressure fuel sent under pressure from the supply pump, holds the
Common rail Common rail
fuel pressure, and distributes the fuel to each injector. fuel pressure, and distributes the fuel to each injector.
Pressure limiter Operates to allow pressure within the common rail to escape if the pressure in the Pressure limiter Operates to allow pressure within the common rail to escape if the pressure in the
(common rail common rail becomes abnormally high. (common rail common rail becomes abnormally high.
component part) component part)
Common rail pressure Detects the pressure inside the common rail, converts it to a voltage, and sends that Common rail pressure Detects the pressure inside the common rail, converts it to a voltage, and sends that
sensor (common rail voltage to the ECM. sensor (common rail voltage to the ECM.
component part) component part)
Injector Controlled by the ECM and injects the fuel. Injector Controlled by the ECM and injects the fuel.
Raise the fuel pressure and send it under pressure to the common rail by using the Raise the fuel pressure and send it under pressure to the common rail by using the
Supply pump Supply pump
force of the engine rotation. force of the engine rotation.
SCV (suction control Controls the fuel pressure (discharge quantity) sent to the common rail. SCV (suction control Controls the fuel pressure (discharge quantity) sent to the common rail.
valve) (supply pump The ECM controls the time during which power is on to the SCV to increase or decrease valve) (supply pump The ECM controls the time during which power is on to the SCV to increase or decrease
component part) the amount of fuel discharged. component part) the amount of fuel discharged.
Fuel temperature Detects the fuel temperature and sends it to the ECM. Fuel temperature Detects the fuel temperature and sends it to the ECM.
sensor (supply pump Used for supply pump control etc. sensor (supply pump Used for supply pump control etc.
component part) component part)
EGR (Exhaust Gas Recirculates part of the exhaust gas in the intake manifold and mixes the EGR gas with EGR (Exhaust Gas Recirculates part of the exhaust gas in the intake manifold and mixes the EGR gas with
Recirculation) the suction air to reduce the combustion temperature and reduce NOx. Recirculation) the suction air to reduce the combustion temperature and reduce NOx.
EGR valve The EGR valve operation (open and close) timing and the lift amount are controlled by EGR valve The EGR valve operation (open and close) timing and the lift amount are controlled by
signals from the ECM. (The valve lift amount is detected by the EGR position sensor) signals from the ECM. (The valve lift amount is detected by the EGR position sensor)
(EGR position sensor) (EGR position sensor)
EGR cooler Cools the high-temperature EGR gas by using the engine coolant. EGR cooler Cools the high-temperature EGR gas by using the engine coolant.
ECM (engine control Constantly monitors the information from each sensor and controls the engine system. ECM (engine control Constantly monitors the information from each sensor and controls the engine system.
module) module)
QOS Determines the glow time according to the engine coolant temperature, operates the QOS Determines the glow time according to the engine coolant temperature, operates the
glow relay, and makes starting at low temperatures easy and also reduces white smoke glow relay, and makes starting at low temperatures easy and also reduces white smoke
(quick on start system) and noise immediately after the engine starts. (quick on start system) and noise immediately after the engine starts.
Sends a signal to the ECM when the projection section of the engine flywheel passes Sends a signal to the ECM when the projection section of the engine flywheel passes
CKP sensor this sensor. CKP sensor this sensor.
(crank position The ECM identifies the cylinders through this sensor input, determines the crank angle, (crank position The ECM identifies the cylinders through this sensor input, determines the crank angle,
sensor) and uses this information to control the fuel injection and to calculate the engine speed. sensor) and uses this information to control the fuel injection and to calculate the engine speed.
In case of trouble in the CKP sensor, the CMP sensor provides a back-up function. In case of trouble in the CKP sensor, the CMP sensor provides a back-up function.
Detects the engine oil pressure and sends it to the ECM. Detects the engine oil pressure and sends it to the ECM.
Oil pressure sensor Oil pressure sensor
Used for oil pressure drop alarms etc. Used for oil pressure drop alarms etc.
Engine coolant Detects the engine coolant temperature and sends it to the ECM. Engine coolant Detects the engine coolant temperature and sends it to the ECM.
temperature sensor Used for fuel injection control, QOS control, etc. temperature sensor Used for fuel injection control, QOS control, etc.
Sends a signal to the ECM when the engine camshaft cam section passes this sensor. Sends a signal to the ECM when the engine camshaft cam section passes this sensor.
The ECM identifies the cylinders through this sensor input, determines the crank angle, The ECM identifies the cylinders through this sensor input, determines the crank angle,
CMP sensor and uses this information to control the fuel injection and to calculate the engine speed. CMP sensor and uses this information to control the fuel injection and to calculate the engine speed.
(cam position sensor) Also provides a back-up function in case of trouble in the CKP sensor. (cam position sensor) Also provides a back-up function in case of trouble in the CKP sensor.
However, if there is trouble in the CMP sensor system, there is no change in the However, if there is trouble in the CMP sensor system, there is no change in the
behavior while the engine turns, but after it stops, restarting is difficult. behavior while the engine turns, but after it stops, restarting is difficult.
Atmospheric pressure Detects the atmospheric pressure and sends it to the ECM. The injection quantity is Atmospheric pressure Detects the atmospheric pressure and sends it to the ECM. The injection quantity is
sensor corrected according to the atmospheric pressure. sensor corrected according to the atmospheric pressure.
Suction air Detects the suction air temperature and sends it to the ECM. Optimizes the fuel Suction air Detects the suction air temperature and sends it to the ECM. Optimizes the fuel
temperature sensor injection quantity. temperature sensor injection quantity.
Detects the boost (suction air pressure) inside the intake pipe and sends it to the ECM. Detects the boost (suction air pressure) inside the intake pipe and sends it to the ECM.
Boost pressure sensor Boost pressure sensor
Used to control fuel injection with the boost pressure. Used to control fuel injection with the boost pressure.
Boost temperature Detects the boost temperature and sends it to the ECM. Used for fuel injection control Boost temperature Detects the boost temperature and sends it to the ECM. Used for fuel injection control
sensor etc. sensor etc.

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2. EGR (Exhaust Gas Recirculation) 2. EGR (Exhaust Gas Recirculation)


A B A B
9 9

10 10
1 1

2 2
C C

7 7

8 8

3 3
4 4
D D
5 6 5 6

1. EGR valve 8. Boost temperature sensor 1. EGR valve 8. Boost temperature sensor
2. EGR position sensor 9. EGR cooler 2. EGR position sensor 9. EGR cooler
3. Engine speed 10. Lead valve (4HK1 & 6HK1 only) 3. Engine speed 10. Lead valve (4HK1 & 6HK1 only)
4. Engine coolant temperature sensor A. Coolant out 4. Engine coolant temperature sensor A. Coolant out
5. Engine load B. Coolant in 5. Engine load B. Coolant in
6. Intake air temperature sensor C. Exhaust gas 6. Intake air temperature sensor C. Exhaust gas
7. Boost pressure sensor D. Suction air 7. Boost pressure sensor D. Suction air
EGR system is an abbreviation of «Exhaust Gas Recirculation» system. The EGR system recirculates part of EGR system is an abbreviation of «Exhaust Gas Recirculation» system. The EGR system recirculates part of
exhaust gas into intake manifold and mixes inactive gases with the suction air to reduce the combustion exhaust gas into intake manifold and mixes inactive gases with the suction air to reduce the combustion
temperature and suppress the generation of nitrogen oxides (NOx). The EGR quantity is controlled by the temperature and suppress the generation of nitrogen oxides (NOx). The EGR quantity is controlled by the
operation (opening and closing) of the EGR valve installed between exhaust manifold and the intake manifold. operation (opening and closing) of the EGR valve installed between exhaust manifold and the intake manifold.
The ERG quantity is determined from the engine speed and engine load ratio (fuel injection quantity) and the The ERG quantity is determined from the engine speed and engine load ratio (fuel injection quantity) and the
EGR amount is controlled. A cooling system (EGR cooler) is installed in the EGR gas path to cool the high- EGR amount is controlled. A cooling system (EGR cooler) is installed in the EGR gas path to cool the high-
temperature EGR gas with this EGR cooler. This cooled EGR gas is mixed with new air intake to make the temperature EGR gas with this EGR cooler. This cooled EGR gas is mixed with new air intake to make the
combustion temperature lower than with normal EGR, which contributes to the reduction of NOx. (Cooled combustion temperature lower than with normal EGR, which contributes to the reduction of NOx. (Cooled
EGR) EGR)
Furthermore, a lead valve is used in the EGR system to suppress EGR gas back flow and allow the EGR gas Furthermore, a lead valve is used in the EGR system to suppress EGR gas back flow and allow the EGR gas
to only flow in one direction. to only flow in one direction.

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3. Relationship between ECM and sensor actuators 3. Relationship between ECM and sensor actuators

Engine Control Module Engine Control Module


Sensor Actuator Sensor Actuator
Trottle signal Trottle signal

Engine speed Injection quantity control Engine speed Injection quantity control
Injection timing control Injection timing control

Cylinder Cylinder
identification signal identification signal

Correction signal Correction signal

Injection pressure control Injection pressure control

1. Throttle volume (Computer A) 1. Throttle volume (Computer A)


2. Crank shaft position sensor 2. Crank shaft position sensor
3. Camshaft position sensor 3. Camshaft position sensor
4. Other sensors 4. Other sensors
5. Injector 5. Injector
6. Common rail pressure sensor 6. Common rail pressure sensor
7. Supply pump 7. Supply pump
8. EGR valve 8. EGR valve

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4001-76 4001-76

4. Cautions for Maintenance 4. Cautions for Maintenance


Cautions concerning fuel used Cautions concerning fuel used
With common rail engines, the supply pump and injector are lubricated by the fuel running through them. With common rail engines, the supply pump and injector are lubricated by the fuel running through them.
Therefore, if any fuel other than diesel is used, this leads to engine trouble, so use of non-specified fuel is Therefore, if any fuel other than diesel is used, this leads to engine trouble, so use of non-specified fuel is
strictly prohibited. strictly prohibited.
Please be aware that troubles resulting from the use of non-specified fuel are not covered by the warranty. Please be aware that troubles resulting from the use of non-specified fuel are not covered by the warranty.
Specified fuel Specified fuel
See section 1002 about detail of CASE approval fuel. See section 1002 about detail of CASE approval fuel.

The parts of the fuel system (injector internal part etc.) and the holes and gaps that form the fuel path are The parts of the fuel system (injector internal part etc.) and the holes and gaps that form the fuel path are
made with extremely high precision made with extremely high precision
Therefore, they are extremely sensitive to foreign matter. Foreign matter in the fuel path can damage it, so Therefore, they are extremely sensitive to foreign matter. Foreign matter in the fuel path can damage it, so
use great care to keep out foreign matter. use great care to keep out foreign matter.
1. Clean and care for the fuel line and its surroundings before starting other maintenance. 1. Clean and care for the fuel line and its surroundings before starting other maintenance.
2. Those working on the fuel line must have hands clean of dirt and dust. Wearing gloves while working is 2. Those working on the fuel line must have hands clean of dirt and dust. Wearing gloves while working is
strictly prohibited. strictly prohibited.
3. After removing fuel hoses and fuel pipes, always seal the hoses and pipes by covering the open sections 3. After removing fuel hoses and fuel pipes, always seal the hoses and pipes by covering the open sections
with plastic bags or the like. with plastic bags or the like.
4. When replacing parts, do not open the packing for the new parts until it is time to install them. 4. When replacing parts, do not open the packing for the new parts until it is time to install them.
5. Do not reuse any gaskets or O-rings. Replace them with new ones. 5. Do not reuse any gaskets or O-rings. Replace them with new ones.
Do not reuse fuel system high pressure fuel lines or injector pipes. If they are removed, replace them Do not reuse fuel system high pressure fuel lines or injector pipes. If they are removed, replace them
with new parts. with new parts.
Do not replace a pressure limiter, fuel temperature sensor or flow damper alone. If there is any Do not replace a pressure limiter, fuel temperature sensor or flow damper alone. If there is any
problem, replace the common rail assembly and all the fuel pipes. problem, replace the common rail assembly and all the fuel pipes.

(6HK1 drawing) (6HK1 drawing)

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4001-77 4001-77
The SCV pump alone cannot be replaced because the fuel temperature sensor is installed on the The SCV pump alone cannot be replaced because the fuel temperature sensor is installed on the
pump main unit. Always replace the supply pump assembly. pump main unit. Always replace the supply pump assembly.

(6HK1 drawing) (6HK1 drawing)

1. Injector pipes 4. Fuel temperature sensor 1. Injector pipes 4. Fuel temperature sensor
2. Flow damper (Orifice only on 4JJ1) 5. Pressure limiter 2. Flow damper (Orifice only on 4JJ1) 5. Pressure limiter
3. Common rail pressure sensor 3. Common rail pressure sensor

If there is engine trouble, it is strictly prohibited to judge individual cylinders as OK or NG by starting If there is engine trouble, it is strictly prohibited to judge individual cylinders as OK or NG by starting
up the engine and loosening the injection pipes (Never do this. The high-pressure fuel sprays out up the engine and loosening the injection pipes (Never do this. The high-pressure fuel sprays out
dangerously.) dangerously.)

(6HK1 drawing) (6HK1 drawing)

1) Loosening when engine starts strictly prohibited. 1) Loosening when engine starts strictly prohibited.

Be careful. High voltage of 118 V or higher is applied to the injectors. Disconnect the battery cable Be careful. High voltage of 118 V or higher is applied to the injectors. Disconnect the battery cable
ground before replacing injectors. ground before replacing injectors.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-78 4001-78
Explanation of Engine Control Explanation of Engine Control
1) Fuel Injection Quantity Correction 1) Fuel Injection Quantity Correction
The ECM calculates the basic injection quantity from the throttle volume boost sensor, CKP sensor, CMP The ECM calculates the basic injection quantity from the throttle volume boost sensor, CKP sensor, CMP
sensor, and other signals. sensor, and other signals.
According to the common rail pressure, engine coolant temperature, and other conditions at this time, the According to the common rail pressure, engine coolant temperature, and other conditions at this time, the
ECM controls the SCV and controls the injector electrified time to attain optimum injection timing and correct ECM controls the SCV and controls the injector electrified time to attain optimum injection timing and correct
the injection quantity. the injection quantity.
2) Starting Q Correction 2) Starting Q Correction
The engine starting Q correction is terminated at the idling speed +α min -1 (+ α depends on the coolant The engine starting Q correction is terminated at the idling speed +α min -1 (+ α depends on the coolant
temperature.). temperature.).
Also, below the system recognition engine speed (30 min-1), the ECM cannot recognize engine rotation, so Also, below the system recognition engine speed (30 min-1), the ECM cannot recognize engine rotation, so
starting Q correction and engine starting become impossible. starting Q correction and engine starting become impossible.
3) Preheat Control (QOS quick on start) 3) Preheat Control (QOS quick on start)
The ECM determines the glow time (pre-glow, glow, and after-glow) according to the engine coolant The ECM determines the glow time (pre-glow, glow, and after-glow) according to the engine coolant
temperature and makes the glow relay operate. temperature and makes the glow relay operate.
The QOS system makes starting at low temperatures easier and reduces white smoke and noise immediately The QOS system makes starting at low temperatures easier and reduces white smoke and noise immediately
after starting. after starting.
When the key is switched ON, the ECM detects the coolant temperature with the signal from the engine When the key is switched ON, the ECM detects the coolant temperature with the signal from the engine
coolant sensor and varies the glow time to always obtain the optimum starting conditions. coolant sensor and varies the glow time to always obtain the optimum starting conditions.
Also, the after-glow function makes it possible to stabilize the idling rotation immediately after starting. Also, the after-glow function makes it possible to stabilize the idling rotation immediately after starting.
Also, if there is trouble in the engine coolant temperature sensor system, control assumes a fixed coolant Also, if there is trouble in the engine coolant temperature sensor system, control assumes a fixed coolant
temperature of -20°C (-4°F) for engine starting and 80°C (176°F) for running. temperature of -20°C (-4°F) for engine starting and 80°C (176°F) for running.
Also, EGR control stops. (Thermostat valve opening temperature 95°C (203°F)) Also, EGR control stops. (Thermostat valve opening temperature 95°C (203°F))
4) Atmospheric Pressure Correction (high altitude correction) 4) Atmospheric Pressure Correction (high altitude correction)
The ECM calculates the current altitude from the atmospheric pressure sensor signals. The ECM calculates the current altitude from the atmospheric pressure sensor signals.
The ECM controls the SCV and controls the injector electrified time to attain optimum fuel flow according to The ECM controls the SCV and controls the injector electrified time to attain optimum fuel flow according to
the altitude and other conditions at the time. the altitude and other conditions at the time.
Also, if there is sensor trouble, control assumes a fixed atmospheric pressure of 80 kPa (equivalent to an Also, if there is sensor trouble, control assumes a fixed atmospheric pressure of 80 kPa (equivalent to an
altitude of 2000 m) and stops EGR control too. altitude of 2000 m) and stops EGR control too.
Altitude Torque Altitude Torque
Output due to environmental change Output due to fuel correction Output due to environmental change Output due to fuel correction

800{590} 800{590}
-1
2000 min 2000 min-1
750{553} {2000 rpm} 750{553} {2000 rpm}
Torque (N-m) (lbf-ft)

Torque (N-m) (lbf-ft)


700{516} 700{516}
650{479} 650{479}
-1
600{442} 2200 min 600{442} 2200 min-1
{2200 rpm} {2200 rpm}
550{406} 550{406}
Output due to environmental change Output due to fuel correction Output due to environmental change Output due to fuel correction
500{369} 500{369}
450{332} 450{332}
400{295} 400{295}
0 500 1000 1500 2000 2500 3000 3500 4000 0 500 1000 1500 2000 2500 3000 3500 4000
{0} {1640} {3281} {4921} {6562} {8202} {9842} {11483} {13123} {0} {1640} {3281} {4921} {6562} {8202} {9842} {11483} {13123}
Altitude (m) (ft) Altitude (m) (ft)
LF04002-012 LF04002-012

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4001-79 4001-79

5) Control for Overheating 5) Control for Overheating


When the engine overheats, in order to protect the engine, if the engine coolant temperature exceeds 100°C When the engine overheats, in order to protect the engine, if the engine coolant temperature exceeds 100°C
(212°F), fuel flow restriction is started. (212°F), fuel flow restriction is started.
If the temperature rises further, the fuel flow is further restricted. If the temperature rises further, the fuel flow is further restricted.
If engine coolant temperature rises to 120°C (248°F), the engine is stopped. If engine coolant temperature rises to 120°C (248°F), the engine is stopped.
The protection function is started 1 minute after the engine star ts (In order to detect a stable coolant The protection function is started 1 minute after the engine star ts (In order to detect a stable coolant
temperature). temperature).

Setting Judgment time Engine control Recovery condition Setting Judgment time Engine control Recovery condition
100°C ECM: Reduced fuel injection quantity - 100°C ECM: Reduced fuel injection quantity -
- -
(212°F) CX controller: Normal (212°F) CX controller: Normal
8th on coolant 7th or lower on coolant 8th on coolant 7th or lower on coolant
105°C 105°C
temperature temperature gradation temperature temperature gradation
(221°F) (221°F)
gradation gradation
110°C ECM: Reduced fuel injection quantity 110°C ECM: Reduced fuel injection quantity
5 seconds 5 seconds
(230°F) CX controller: Idling (230°F) CX controller: Idling
120°C ECM: Reduced fuel injection quantity Key switched ON after engine 120°C ECM: Reduced fuel injection quantity Key switched ON after engine
5 seconds 5 seconds
(248°F) CX controller: Engine stopped stopped (248°F) CX controller: Engine stopped stopped

• The protection function does not work if any of the error codes below occurs. • The protection function does not work if any of the error codes below occurs.
0117 (Coolant temperature sensor abnormally low voltage) 0117 (Coolant temperature sensor abnormally low voltage)
0118 (Coolant temperature sensor abnormally high voltage) 0118 (Coolant temperature sensor abnormally high voltage)
2104 (Faulty CAN bus) 2104 (Faulty CAN bus)
2106 (Faulty CAN time-out) 2106 (Faulty CAN time-out)
0090 (CAN communication error) 0090 (CAN communication error)

100°C 100°C
(212°F) Flow restriction start (212°F) Flow restriction start
100% 100%

Fuel Fuel
Flow 110°C Control of idling rotation Flow 110°C Control of idling rotation
(230°F) (230°F)

0% 0%
105°C 120°C 105°C 120°C
(221°F) (248°F) (221°F) (248°F)
Overheat alarm Engine stop Overheat alarm Engine stop

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4001-80 4001-80

6) Control for Boost Temperature Rise 6) Control for Boost Temperature Rise
If the boost temperature exceeds 80°C (176°F), fuel flow restriction is started. If the boost temperature exceeds 80°C (176°F), fuel flow restriction is started.
If temperature rises to 90°C (194°F), the engine is stopped. If temperature rises to 90°C (194°F), the engine is stopped.
The protection function is star ted 1 minute after the engine star ts. (In order to detect a stable boost The protection function is star ted 1 minute after the engine star ts. (In order to detect a stable boost
temperature) temperature)

Judgment Engine control Recovery condition Judgment Engine control Recovery condition
Setting Setting
time time
80°C ECM: Normal State of 70°C (158°F) or less 80°C ECM: Normal State of 70°C (158°F) or less
5 seconds 5 seconds
(176°F) CX controller: Idling control continues for 30s (176°F) CX controller: Idling control continues for 30s
90°C ECM: Normal Key switched ON after engine 90°C ECM: Normal Key switched ON after engine
5 seconds 5 seconds
(194°F) CX controller: Engine stop control stopped (194°F) CX controller: Engine stop control stopped

• The protection function does not work if any of the error codes below occurs. • The protection function does not work if any of the error codes below occurs.
1112 (Boost temperature sensor abnormally low voltage) 1112 (Boost temperature sensor abnormally low voltage)
1113 (Boost temperature sensor abnormally high voltage) 1113 (Boost temperature sensor abnormally high voltage)
2104 (Faulty CAN bus) 2104 (Faulty CAN bus)
2106 (Faulty CAN time-out) 2106 (Faulty CAN time-out)
0090 (CAN communication error) 0090 (CAN communication error)
7) Control for Engine Oil Pressure Drop 7) Control for Engine Oil Pressure Drop
If the engine oil pressure drops, the engine is stopped to prevent engine damage. If the engine oil pressure drops, the engine is stopped to prevent engine damage.
The protection function is started 30s after the engine starts. (In order to detect a stable engine oil pressure) The protection function is started 30s after the engine starts. (In order to detect a stable engine oil pressure)

Judgment Engine control Recovery condition Judgment Engine control Recovery condition
Setting Setting
time time
ECM: Normal Key switched ON after engine ECM: Normal Key switched ON after engine
40 kPa 5 seconds 40 kPa 5 seconds
CX controller: Engine stop control stopped CX controller: Engine stop control stopped

• The protection function does not work if any of the error codes below occurs. • The protection function does not work if any of the error codes below occurs.
0522 (Oil pressure sensor abnormally low voltage) 0522 (Oil pressure sensor abnormally low voltage)
0523 (Oil pressure sensor abnormally high voltage) 0523 (Oil pressure sensor abnormally high voltage)
2104 (Faulty CAN bus) 2104 (Faulty CAN bus)
2106 (Faulty CAN time-out) 2106 (Faulty CAN time-out)
0090 (CAN communication error) 0090 (CAN communication error)
1633 (Faulty 5 V power supply 3 voltage/sensor power supply) 1633 (Faulty 5 V power supply 3 voltage/sensor power supply)
8) Start Control (coolant temperature monitoring) 8) Start Control (coolant temperature monitoring)
When the coolant temperature is 0°C (32°F) or lower, the ECM controls the fuel amount depending on the When the coolant temperature is 0°C (32°F) or lower, the ECM controls the fuel amount depending on the
coolant temperature, for stable engine starting. coolant temperature, for stable engine starting.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-81 4001-81

9) Long Cranking Control 9) Long Cranking Control


For the purpose of reducing black smoke when starting the engine and as backup in case adequate starting Q For the purpose of reducing black smoke when starting the engine and as backup in case adequate starting Q
(fuel injection) is not obtained, for example due to injector wear, after the stipulated time after the start of (fuel injection) is not obtained, for example due to injector wear, after the stipulated time after the start of
cranking, the starting Q is raised the stipulated amount to improve startability. cranking, the starting Q is raised the stipulated amount to improve startability.

Pattern with normal Pattern in with cranking time is at least 1 second Pattern with normal Pattern in with cranking time is at least 1 second
cranking time cranking time

Key switch Key switch


1 second 1 second

Idling cranking Idling cranking

Engine Speed Engine Speed

Starting Q Starting Q

ST-Q. Standard starting Q NL-Q. Q for no load ST-Q. Standard starting Q NL-Q. Q for no load
UP-Q. Starting Q after increase UP-Q. Starting Q after increase
10)Starting Control for Reduced Number of Cylinders 10)Starting Control for Reduced Number of Cylinders
When the fact that there is a stopped injector is detected with trouble diagnosis (when an error code is When the fact that there is a stopped injector is detected with trouble diagnosis (when an error code is
detected), for the purpose of emergency escape, the fuel injection quantity is corrected to secure engine detected), for the purpose of emergency escape, the fuel injection quantity is corrected to secure engine
startability. startability.
The injection quantity for the troubled injector is allocated to the normal injectors. (The total injection The injection quantity for the troubled injector is allocated to the normal injectors. (The total injection
quantity is made the same.) quantity is made the same.)
• The injector correction factors are as follows. • The injector correction factors are as follows.

Number of effective cylinders 4 3 2 1 0 Number of effective cylinders 4 3 2 1 0


Correction factor 1.0 1.33 2.0 1.0 1.0 Correction factor 1.0 1.33 2.0 1.0 1.0

CAUTION: No control if there is trouble in injectors for 5 or more cylinders. No control if an injector CAUTION: No control if there is trouble in injectors for 5 or more cylinders. No control if an injector
has a mechanical trouble. has a mechanical trouble.
11) Normal Stop (key switch OFF operation) 11) Normal Stop (key switch OFF operation)
1. The key switch is set OFF. 1. The key switch is set OFF.
2. When the ECM recognizes that the key is OFF, [3.] to [5.] are carried out at the same time. 2. When the ECM recognizes that the key is OFF, [3.] to [5.] are carried out at the same time.
3. Injector injection quantity calculation stop 3. Injector injection quantity calculation stop
4. Suction control valve (SCV) full close instruction 4. Suction control valve (SCV) full close instruction
5. EGR valve full close instruction, EGR valve initial correction 5. EGR valve full close instruction, EGR valve initial correction
6. When the operations in [3.] to [5.] end, the trouble log etc. are written to the EEPROM in the ECM. 6. When the operations in [3.] to [5.] end, the trouble log etc. are written to the EEPROM in the ECM.
7. The main relay is switched OFF and the power feed to the ECM is switched OFF. 7. The main relay is switched OFF and the power feed to the ECM is switched OFF.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-82 4001-82

5. Engine Start/Stop Judgment 5. Engine Start/Stop Judgment


Engine start and stop is judged based on the engine speed sent from the ECM with CAN communications. Engine start and stop is judged based on the engine speed sent from the ECM with CAN communications.
Judgment value: Judgment value:

Start: 500 min-1 (500 rpm) Start: 500 min-1 (500 rpm)
Stop: 200 min-1 (200 rpm) Stop: 200 min-1 (200 rpm)

Starting Starting

Stop Stop
200 min-1 500 min-1 200 min-1 500 min-1
{200 rpm} {500 rpm} {200 rpm} {500 rpm}

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4001-83 4001-83
SERVICE SUPPORT SERVICE SUPPORT

Screen Operations Screen Operations


1) Screen Shift 1) Screen Shift

Key ON Key ON

(Anti-theft protection ON) (Anti-theft protection ON)

(Authentication OK) (Authentication OK)


(Anti-theft protection OFF) (Anti-theft protection OFF)

(Model selection not completed) (Model selection not completed)

(Authentication OK) (Authentication OK)

(Model selection completed) One-touch (Model selection completed) One-touch


idle switch idle switch
pressed 5 times pressed 5 times
All reset All reset

No error No error
3 seconds 3 seconds
Breaker or crusher switch Breaker or crusher switch
3 seconds elapse 3 seconds 3 seconds elapse 3 seconds
Flow reset Flow reset

10 seconds 10 seconds

1 second 3 seconds 1 second 3 seconds

Main Unit Main Unit


3 seconds (Service) 3 seconds (Service)
1 second 1 second

(Engine Service) (Engine Service)


DIAG reset DIAG reset

10 seconds 10 seconds

or HR reset or HR reset

10 seconds 10 seconds

CFG reset CFG reset

10 seconds 10 seconds

Exit this mode by Exit this mode by


switching OFF the switching OFF the
key key

Screen on which the engine S/N, Screen on which the engine S/N,
Q adjustment, and QR can be Q adjustment, and QR can be
viewed viewed

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-84 4001-84
a) Operation for shifting to service support screen a) Operation for shifting to service support screen
1. If both the travel high-speed switch and the horn volume select switch on the switch panel are held down 1. If both the travel high-speed switch and the horn volume select switch on the switch panel are held down
for 3 seconds, the display switches to the service support screen. for 3 seconds, the display switches to the service support screen.
2. If both the high-speed travel switch and the horn volume select switch on the switch panel are held down 2. If both the high-speed travel switch and the horn volume select switch on the switch panel are held down
again for 1 second, the display returns to the normal screen. again for 1 second, the display returns to the normal screen.

Normal screen Service support screen Normal screen Service support screen

Hold down for 024.6 Hold down for 024 .6


3 seconds 1800 013.7
3 seconds 1800 013 .7
0350 02.56 0350 02. 56
Hold down for 0120 00.93 Hold down for 0120 00. 93
1 second 1 second
b) Service support screen switching operation b) Service support screen switching operation

B C B C
1 2 3 1 2 3
D D
CHK MA I N 1 P1 000.0 MPa C HK MAIN 1 P1 000.0 MPa
Eng 0000 min-1 P2 000.0 MPa Eng 0000 min-1 P2 000.0 MPa
Power 0000 mA N1 00.00 MPa Power 0000 mA N1 00.00 MPa
Flow 0000 mA N2 00.00 MPa Flow 0000 mA N2 00.00 MPa

A A
A Mode select switch 1 Mode (switching with high speed travel switch A) A Mode select switch 1 Mode (switching with high speed travel switch A)
B Section select switch 2 Section (switching with horn volume select switch B) B Section select switch 2 Section (switching with horn volume select switch B)
C Page (-) 3 Page ( switching: forward with light switch D and back with C Page (-) 3 Page ( switching: forward with light switch D and back with
D Page (+) washer switch C) D Page (+) washer switch C)

[Mode] [Section] [Page] [Mode] [Section] [Page]

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-85 4001-85
Screen Display List Screen Display List
1. CHK (status display) Screen List 1. CHK (status display) Screen List
In CHK mode, in addition to the machine status (milli-amp, oil pressures, temperatures, etc.), it is possible to In CHK mode, in addition to the machine status (milli-amp, oil pressures, temperatures, etc.), it is possible to
check sensor and switch input/output states, as well as the angle, load ratio and work radius, etc. at the check sensor and switch input/output states, as well as the angle, load ratio and work radius, etc. at the
applied machine (liftcrane application machine, lifting magnet machine). applied machine (liftcrane application machine, lifting magnet machine).
Section Section
Select switch Select switch
Page (-) Page (-)
Page (+) Page (+)

1 Section 2 Page 1 Section 2 Page


NOTE: From the CHK mode screen, if the wiper switch and the light switch are held down for 3 seconds, NOTE: From the CHK mode screen, if the wiper switch and the light switch are held down for 3 seconds,
the display shifts to the model selection screen. the display shifts to the model selection screen.

A) MAIN A) MAIN
1) Engine and pump 1) Engine and pump
Eng : Engine speed Eng : Engine speed
CHK MAI N 1 P1 000.0 MPa Power : Actual milli-amp for horsepower control C HK MA I N 1 P1 000.0 MPa Power : Actual milli-amp for horsepower control
proportional valve proportional valve
Eng 0000 min -1 P2 000.0 MPa Eng 0000 min -1 P2 000.0 MPa
Flow : Actual milli-amp for flow control proportional Flow : Actual milli-amp for flow control proportional
Power 0000 mA N1 00.00 MPa valve Power 0000 mA N1 00.00 MPa valve
Flow 0000 N2 00.00 P1 : Pump1 Discharge pressure Flow 0000 N2 00.00 P1 : Pump1 Discharge pressure
mA MPa mA MPa
P2 : Pump2 Discharge pressure P2 : Pump2 Discharge pressure
N1 : Pump1 Negative control pressure N1 : Pump1 Negative control pressure
N2 : Pump2 Negative control pressure N2 : Pump2 Negative control pressure

2) Temperature and pressure 2) Temperature and pressure


Coolnt : Radiator coolant temperature Coolnt : Radiator coolant temperature
CHK MA I N 2 Baro 0000 h Pa HydOil : Hydraulic oil temperature CH K M AI N 2 Baro 0000 h Pa HydOil : Hydraulic oil temperature
Coolnt 0000 EngOil 0000 FuelT : Fuel temperature Coolnt 0000 EngOil 0000 FuelT : Fuel temperature
˚C k Pa ˚C k Pa
Baro : Barometric pressure Baro : Barometric pressure
HydOil 0000 ˚C BstT 0000 ˚C EngOil : Engine oil pressure HydOil 0000 ˚C BstT 0000 ˚C EngOil : Engine oil pressure
FuelT 0000 ˚C Air 0000 ˚C BstT : Boost temperature FuelT 0000 ˚C Air 0000 ˚C BstT : Boost temperature
Air : Suction air temperature Air : Suction air temperature

3) Load and boost 3) Load and boost


Eng : Engine speed Eng : Engine speed
CHK MA I N 3 P1 000.0 MPa Load : Load ratio C HK MA I N 3 P1 000.0 MPa Load : Load ratio
Power : Actual milli-amp for horsepower control Power : Actual milli-amp for horsepower control
Eng 0000 min-1 P2 000.0 MPa proportional valve
Eng 0000 min-1 P2 000.0 MPa proportional valve
Load 0000 % BstT 0000 ˚C P1 : Pump 1 Discharge pressure Load 0000 % BstT 0000 ˚C P1 : Pump 1 Discharge pressure
P2 : Pump 2 Discharge pressure P2 : Pump 2 Discharge pressure
Power 0000 mA BstP 0000 kPa Power 0000 mA BstP 0000 kPa
BstT : Boost temperature BstT : Boost temperature
BstP : Boost pressure BstP : Boost pressure

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4001-86 4001-86
4) Load and milli-amp for horsepower control proportional valve 4) Load and milli-amp for horsepower control proportional valve
Eng : Engine speed Eng : Engine speed
CHK MAI N 4 P1 000.0 MPa Load : Load ratio CH K M AI N 4 P1 000.0 MPa Load : Load ratio
Eng 0000 min -1 P2 000.0 MPa Power : Actual milli-amp for horsepower control Eng 0000 min -1 P2 000.0 MPa Power : Actual milli-amp for horsepower control
proportional valve proportional valve
Load 0000 % N1 00.00 MPa P1 : Pump 1 Discharge pressure Load 0000 % N1 00.00 MPa P1 : Pump 1 Discharge pressure
Power 0000 mA N2 00.00 MPa P2 : Pump 2 Discharge pressure Power 0000 mA N2 00.00 MPa P2 : Pump 2 Discharge pressure
N1 : Pump 1 Negative control pressure N1 : Pump 1 Negative control pressure
N2 : Pump 2 Negative control pressure N2 : Pump 2 Negative control pressure

5) Target and actual milli-amp for horsepower control proportional valve 5) Target and actual milli-amp for horsepower control proportional valve
Eng : Engine speed Eng : Engine speed
CH K MAI N 5 -4- Load : Load ratio C HK MA I N 5 -4- Load : Load ratio
Power : Actual milli-amp for horsepower control Power : Actual milli-amp for horsepower control
Eng 0000 min-1 tEng 0000 min -1 proportional valve
Eng 0000 min-1 tEng 0000 min -1 proportional valve
Load 0000 % ThVol 0000 % -4- : * Load 0000 % ThVol 0000 % -4- : *
Power 0000 tPower 0000 tEng : Target engine speed Power 0000 tPower 0000 tEng : Target engine speed
mA mA mA mA
ThVol : Throtle volume degree of opening ThVol : Throtle volume degree of opening
tPower : Target milli-amp for horsepower control tPower : Target milli-amp for horsepower control
proportional valve proportional valve

6) Target and actual milli-amp for flow control proportional valve 6) Target and actual milli-amp for flow control proportional valve
Eng : Engine speed Eng : Engine speed
CHK MAIN 6 P1 000.0 MPa Power : Actual milli-amp for horsepower control CHK MAIN 6 P1 000.0 MPa Power : Actual milli-amp for horsepower control
Eng 0000 min -1 N1 00.00 MPa proportional valve Eng 0000 min -1 N1 00.00 MPa proportional valve
Flow : Actual milli-amp for flow control proportional Flow : Actual milli-amp for flow control proportional
Power 0000 mA Swg 00.00 MPa valve Power 0000 mA Swg 00.00 MPa valve
Flow 0000 mA tFlow 0000 mA P1 : Pump 1 Discharge pressure Flow 0000 mA tFlow 0000 mA P1 : Pump 1 Discharge pressure
N1 : Pump 1 Negative control pressure N1 : Pump 1 Negative control pressure
Swg : Swing pilot pressure Swg : Swing pilot pressure
tFlow : Target milli-amp for flow control proportional tFlow : Target milli-amp for flow control proportional
valve valve

7) Target and actual milli-amp for hydraulic fan proportional valve 7) Target and actual milli-amp for hydraulic fan proportional valve
Eng : Engine speed Eng : Engine speed
CH K MAIN 7 HydOil 0000 ˚C Coolnt : Radiator coolant temperature CH K M AI N 7 HydOil 0000 ˚C Coolnt : Radiator coolant temperature
Fan : Actual milli-amp for hydraulic fan proportional Fan : Actual milli-amp for hydraulic fan proportional
Eng 0000 min-1 FuelT 0000 ˚C valve
Eng 0000 min-1 FuelT 0000 ˚C valve
Coolnt 0000 ˚C BstT 000 ˚C HydOil : Hydraulic oil temperature Coolnt 0000 ˚C BstT 000 ˚C HydOil : Hydraulic oil temperature
FuelT : Fuel temperature FuelT : Fuel temperature
Fan 0000 mA tFan 000 mA Fan 0000 mA tFan 000 mA
BstT : Boost temperature BstT : Boost temperature
tFan : Target milli-amp for hydraulic fan proportional tFan : Target milli-amp for hydraulic fan proportional
valve valve

8) Pilot pressure 8) Pilot pressure


P1 : Pump1 Discharge pressure P1 : Pump1 Discharge pressure
CHK MAI N 8 Upr 00.00 MPa P2 : Pump2 Discharge pressure CH K M AI N 8 Upr 00.00 MPa P2 : Pump2 Discharge pressure
Cyl(B) : Boom bottom pressure Cyl(B) : Boom bottom pressure
P1 000.0 MPa Swg 00.00 MPa P1 000.0 MPa Swg 00.00 MPa
Upr : Upper pilot pressure Upr : Upper pilot pressure
P2 000.0 MPa Trv 00.00 MPa Swg : Swing pilot pressure P2 000.0 MPa Trv 00.00 MPa Swg : Swing pilot pressure
Cyl(B) 000.0 MPa AmCls 00.00 MPa Trv : Travel pilot pressure Cyl(B) 000.0 MPa AmCls 00.00 MPa Trv : Travel pilot pressure
AmCls : Arm-in pilot pressure AmCls : Arm-in pilot pressure

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-87 4001-87

9) Hydraulic circuits; Input/ouput and pressure 9) Hydraulic circuits; Input/ouput and pressure
P1 : Pump1 Discharge pressure P1 : Pump1 Discharge pressure
CHK MA I N 9 P1 000.0 MPa P2 : Pump2 Discharge pressure CHK M AI N 9 P1 000.0 MPa P2 : Pump2 Discharge pressure
In P2 000.0 N1 : Pump1 Negative control pressure In P2 000.0 N1 : Pump1 Negative control pressure
MPa MPa
N2 : Pump2 Negative control pressure N2 : Pump2 Negative control pressure
Out1 N1 00.00 MPa Out1 N1 00.00 MPa
Out2 N2 00.00 MPa Out2 N2 00.00 MPa

Hydraulic circuit input /output state ( = OFF, = ON ) Hydraulic circuit input /output state ( = OFF, = ON )

In Out1 Out2 In Out1 Out2


1 5 9 1 5 9
2 6 10 2 6 10
3 7 11 3 7 11
4 8 12 4 8 12
1 Pressure sensor; Arm in 7 Solenoid; Boost 1 Pressure sensor; Arm in 7 Solenoid; Boost
2 Pressure sensor; Travel 8 Solenoid; Swing brake 2 Pressure sensor; Travel 8 Solenoid; Swing brake
3 Pressure sensor; Swing 9 Relay; Travel alarm 3 Pressure sensor; Swing 9 Relay; Travel alarm
4 Pressure sensor; Upper 10 Solenoid; Fan reverse (large machine only) 4 Pressure sensor; Upper 10 Solenoid; Fan reverse (large machine only)
5 Solenoid; Free swing / beacon 11 Solenoid; Option line switchover 5 Solenoid; Free swing / beacon 11 Solenoid; Option line switchover
6 Solenoid; Travel high-speed switchover 12 Solenoid; Power save 6 Solenoid; Travel high-speed switchover 12 Solenoid; Power save

10) Electrical circuits; Input/ouput 10) Electrical circuits; Input/ouput


Eng : Engine speed Eng : Engine speed
CHK MA I N 10 Eng 0000 -1 Coolnt : Radiator coolant temperature CHK M AI N 10 Eng 0000 -1 Coolnt : Radiator coolant temperature
min min
Batt : Battery voltage Batt : Battery voltage
In Coolnt 0000 ˚c In Coolnt 0000 ˚c
FuelLv : Fuel sensor FuelLv : Fuel sensor
Out1 Batt 0000 V Out1 Batt 0000 V
Out2 FuelLv 0000 % Out2 FuelLv 0000 %

Electrical circuit input /output state ( = OFF, = ON ) Electrical circuit input /output state ( = OFF, = ON )

In Out1 Out2 In Out1 Out2


*
1
*
4
*7 *
1
*
4
*7
2 5 8 2 5 8
3 6 9 3 6 9

1 Switch; Anti-theft protection 6 Glow signal 1 Switch; Anti-theft protection 6 Glow signal
2 Battery charge 7 Engine stop due to trouble 2 Battery charge 7 Engine stop due to trouble
3 Switch; Key 8 Low idle restriction due to trouble 3 Switch; Key 8 Low idle restriction due to trouble
4 A/C coolant temprerature transmission 9 Restriction on milli-amp for horsepower control 4 A/C coolant temprerature transmission 9 Restriction on milli-amp for horsepower control
5 Relay; Feed pump automatic stop proportional valve due to trouble 5 Relay; Feed pump automatic stop proportional valve due to trouble

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-88 4001-88
B) MNT B) MNT
1) Computer S Information 1) Computer S Information

* The longitude and latitude are displayed when the continuous GPS * The longitude and latitude are displayed when the continuous GPS
position measurement time is 5 minutes or longer. position measurement time is 5 minutes or longer.

CHK MNT 2 4 0052 1 0605 CH K M NT 2 4 0052 1 0605

1 0605 5 0130 2 2803 9 1 0605 5 0130 2 2803 9


2 2803 6 0130 3 1432 2 2803 6 0130 3 1432

3 1432 7 0122 4 0052 10 3 1432 7 0122 4 0052 10

* UTC (universal time coordinate) is the global standard time.


5 0130 11 * UTC (universal time coordinate) is the global standard time.
5 0130 11
* Displayed after the completion of GPS position measurement. 6 0130 * Displayed after the completion of GPS position measurement. 6 0130
* For 3D position measurement, the altitude can be measured. 12 * For 3D position measurement, the altitude can be measured. 12
* GCC is a land station. 130 is the GCC for Japan (122 is South Korea). 7 0122 * GCC is a land station. 130 is the GCC for Japan (122 is South Korea). 7 0122

1 GPS continuous position measurement time (for example, 5 minutes 30 second of continuous position 1 GPS continuous position measurement time (for example, 5 minutes 30 second of continuous position
measurement) measurement)
2 Computer S part number bottom 4 digit display (example, KHR14401) 2 Computer S part number bottom 4 digit display (example, KHR14401)
3 Latitude: inside the O, 0 = North hemisphere, 1 = Southern hemisphere (example, 35 degrees 47.83 minutes) 3 Latitude: inside the O, 0 = North hemisphere, 1 = Southern hemisphere (example, 35 degrees 47.83 minutes)
4 Longitude: inside the O, 0 = Longitude east, 1 = Longitude west (example, 140 degrees 41.32 minutes 4 Longitude: inside the O, 0 = Longitude east, 1 = Longitude west (example, 140 degrees 41.32 minutes
longitude east) longitude east)
5 GPS position measurement status 5 GPS position measurement status
0 = GPS not yet operating 0 = GPS not yet operating
1 = GPS measuring 1 = GPS measuring
2 = 2D measurement status 2 = 2D measurement status
3 = 3D measurement status 3 = 3D measurement status
8 = Faulty GPS module 8 = Faulty GPS module
9 = Faulty GPS antenna 9 = Faulty GPS antenna
6 Satellite communications status 6 Satellite communications status
0 = No Satellite data acquired 0 = No Satellite data acquired
1 = Satellite data acquired 1 = Satellite data acquired
9 = Satellite communications abnormal 9 = Satellite communications abnormal
7 Default setting send status 7 Default setting send status
0 = Waiting for default settings send 0 = Waiting for default settings send
1 = Waiting due to sending currently being prohibited 1 = Waiting due to sending currently being prohibited
2 = Resending default settings 2 = Resending default settings
3 = Default setting send complete, sending stopped 3 = Default setting send complete, sending stopped
4 = Default setting send complete, sending permitted 4 = Default setting send complete, sending permitted
8 Blank 8 Blank
9 UTC (Universal Time Coordinate) (example: May 28, 2006, 03:14:32) 9 UTC (Universal Time Coordinate) (example: May 28, 2006, 03:14:32)
10 Altitude (Example: 52 m) 10 Altitude (Example: 52 m)
11 Send GCC number 11 Send GCC number
12 Data acquisition GCC number 12 Data acquisition GCC number

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-89 4001-89

Event send setting Event send setting


The default state is fuel volume warning, anti-theft operation warning event send inhibited. The default state is fuel volume warning, anti-theft operation warning event send inhibited.
These can be changed to enabled with signals from the web server. When this signal is received, No. 4 becomes the These can be changed to enabled with signals from the web server. When this signal is received, No. 4 becomes the
display below. display below.

Fuel volume Anti-theft operation warning Anti-theft operation warning Fuel volume Anti-theft operation warning Anti-theft operation warning
Nr. 4 warning (without position information) (with position information) Nr. 4 warning (without position information) (with position information)
0028 Inhibited Inhibited Inhibited 0028 Inhibited Inhibited Inhibited
0156 Enabled Inhibited Inhibited 0156 Enabled Inhibited Inhibited
0220 Enabled Enabled Inhibited 0220 Enabled Enabled Inhibited
0188 Enabled Inhibited Enabled 0188 Enabled Inhibited Enabled
0092 Inhibited Enabled Inhibited 0092 Inhibited Enabled Inhibited
0060 Inhibited Inhibited Enabled 0060 Inhibited Inhibited Enabled

1 Engine start enable setting 1 Engine start enable setting


0 = Inhibited, 1 = Enabled 0 = Inhibited, 1 = Enabled
2 Send destination count 2 Send destination count
* The send destination is the server, so it is fixed at 1. * The send destination is the server, so it is fixed at 1.
3 Time until next sending (example: 3 hours 24 minutes more until the next sending) 3 Time until next sending (example: 3 hours 24 minutes more until the next sending)
4 Send wait message count (example: 2) 4 Send wait message count (example: 2)
5 Q1200 status 5 Q1200 status
0 = Waiting 0 = Waiting
1 = Sending 1 = Sending
4 = Receiving 4 = Receiving
5 = Receiving complete 5 = Receiving complete
6 Send distribution setting 6 Send distribution setting
0248 = STD 0248 = STD
0252 = Liftcrane specifications 0252 = Liftcrane specifications
7 Event send setting 0028 = Default setting 7 Event send setting 0028 = Default setting
8 Send inhibition setting 8 Send inhibition setting
0 = Sending default settings 0 = Sending default settings
128 = Default settings send complete 128 = Default settings send complete

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-90 4001-90

C) H / W-A C) H / W-A
1) Digital input / output 1) Digital input / output

CHK H / W -A 1 DI1 CH K H /W -A 1 DI1


DO1 DI2 DO1 DI2
DO2 DI3 DO2 DI3
DO3 DI4 DO3 DI4
Input /output state ( = OFF, = ON ) Input /output state ( = OFF, = ON )

DO1 DO2 DO3 DO1 DO2 DO3


1 5 1 5
2 6
* 2 6
*
3 7
* 3 7
*
4 8
*9 4 8
*9
DI1 DI2 DI1 DI2
10 14 10 14
11 15 11 15
12 16 12 16
13 17 13 17
DI3 DI4 DI3 DI4
* 20 * 20
*
18
21
22
*
18
21
22
19 19
* *
1 Solenoid; Power save 12 Switch; Anti-theft 1 Solenoid; Power save 12 Switch; Anti-theft
2 Solenoid; Boost 13 Switch; One-touch idle 2 Solenoid; Boost 13 Switch; One-touch idle
3 Solenoid; Travel high-speed switchover 14 Switch; Travel alarm / overload 3 Solenoid; Travel high-speed switchover 14 Switch; Travel alarm / overload
4 Solenoid; Swing brake 15 Switch; Free Swing (North America) 4 Solenoid; Swing brake 15 Switch; Free Swing (North America)
5 Buzzer; Travel alarm 16 Switch; Pressure (2nd option) 5 Buzzer; Travel alarm 16 Switch; Pressure (2nd option)
6 Solenoid; Option line switchover 17 Switch; Pressure (Option) 6 Solenoid; Option line switchover 17 Switch; Pressure (Option)
7 Solenoid; Free swing (North America) 18 Switch; Fan reverse (large machine only) 7 Solenoid; Free swing (North America) 18 Switch; Fan reverse (large machine only)
8 Solenoid Fan reverse (large machine only) 19 Switch; Clog (Return filter) 8 Solenoid Fan reverse (large machine only) 19 Switch; Clog (Return filter)
9 Relay; Feed pump 20 Alternator 9 Relay; Feed pump 20 Alternator
10 Switch; Clog (Air cleaner) 21 Switch; Engine emergency stop 10 Switch; Clog (Air cleaner) 21 Switch; Engine emergency stop
11 Switch; Level Coolant 22 Switch; Key 11 Switch; Level Coolant 22 Switch; Key

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-91 4001-91

2) Digital output / output monitor 2) Digital output / output monitor

CHK H / W -A 2 -4- CH K H /W -A 2 -4-


DO1 DOM1 DO1 DOM1
DO2 DOM2 DO2 DOM2
DO3 DOM3 DO3 DOM3

Input /output state ( = OFF, = ON ) Input /output state ( = OFF, = ON )

DO1 DO2 DO3 DO1 DO2 DO3


1 5 1 5
2 6
* 2 6
*
3 7
* 3 7
*
4 8
*
9 4 8
*
9
-4- DOM1 -4- DOM1

* 1 * 1
* 2 * 2
* 3 * 3
* 4 * 4
DOM2 DOM3 DOM2 DOM3
5 * 5 *
6 6
7
* 7
*
8
*
9 8
*
9
1 Solenoid; Power save 6 Solenoid; Option line switchover 1 Solenoid; Power save 6 Solenoid; Option line switchover
2 Solenoid; Boost 7 Solenoid; Free swing ( North America) 2 Solenoid; Boost 7 Solenoid; Free swing ( North America)
3 Solenoid; Travel high-speed switchover 8 Solenoid; Fan reverse (large machine only) 3 Solenoid; Travel high-speed switchover 8 Solenoid; Fan reverse (large machine only)
4 Solenoid; Swing brake 9 Relay; Feed pump 4 Solenoid; Swing brake 9 Relay; Feed pump
5 Buzzer; Travel Alarm (North America) 5 Buzzer; Travel Alarm (North America)

3) Potentio-meter voltage 3) Potentio-meter voltage


Pot1 : Sensor pressure P1 Pot1 : Sensor pressure P1
CHK H / W -A 3 Pot4 0000 V Pot2 : Sensor pressure P2 C HK H /W -A 3 Pot4 0000 V Pot2 : Sensor pressure P2
Pot3 : Sensor pressure N1 Pot3 : Sensor pressure N1
Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V
Pot4 : Sensor pressure N2 Pot4 : Sensor pressure N2
Pot2 0000 V Pot6 0000 V Pot5 : Sensor pressure Swing Pot2 0000 V Pot6 0000 V Pot5 : Sensor pressure Swing
Pot3 0000 V Pot7 0000 V Pot6 : Sensor pressure Upper Pot3 0000 V Pot7 0000 V Pot6 : Sensor pressure Upper
Pot7 : Sensor pressure Travel Pot7 : Sensor pressure Travel

4) Potentio-meter and sensor voltage (Resistance) 4) Potentio-meter and sensor voltage (Resistance)
Pot8 : Sensor pressure Arm in Pot8 : Sensor pressure Arm in
CHK H / W -A 4 Sn1 0000 V Pot9 : Sensor throttle CHK H /W -A 4 Sn1 0000 V Pot9 : Sensor throttle
Pot10 : Sensor pressure Overload Pot10 : Sensor pressure Overload
Pot8 0000 V Sn2 0000 V Pot8 0000 V Sn2 0000 V
Sn1 : Sensor temperature Hydraulic oil Sn1 : Sensor temperature Hydraulic oil
Pot9 0000 V Sn1 0000 Ω Sn2 : Sensor level Fuel Pot9 0000 V Sn1 0000 Ω Sn2 : Sensor level Fuel
Pot10 0000 V Sn2 0000 Ω Sn1 : Sensor temperature Hydraulic oil Pot10 0000 V Sn2 0000 Ω Sn1 : Sensor temperature Hydraulic oil
Sn2 : Sensor level Fuel Sn2 : Sensor level Fuel

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-92 4001-92
5) PWM data 5) PWM data
PWM# : PWM channel number PWM# : PWM channel number
actcur : Actual milli-amp for horsepower control actcur : Actual milli-amp for horsepower control
proportional valve proportional valve
tgtcur : Target milli-amp for horsepower control tgtcur : Target milli-amp for horsepower control
proportional valve proportional valve
duty : Duty duty : Duty
freq : Frequency freq : Frequency
volt : Voltage volt : Voltage
ovc : Overcurrent detection status ovc : Overcurrent detection status
(+: Overcurrent, - Normal) (+: Overcurrent, - Normal)

6) PWM data 6) PWM data


PWM# : PWM channel number PWM# : PWM channel number
actcur : A c t u a l m i l l i - a m p fo r h y d r a u l i c fa n actcur : A c t u a l m i l l i - a m p fo r h y d r a u l i c fa n
proportional valve proportional valve
tgtcur : Ta r g e t m i l l i - a m p fo r hy d r a u l i c fa n tgtcur : Ta r g e t m i l l i - a m p fo r hy d r a u l i c fa n
proportional valve proportional valve
duty : Duty duty : Duty
freq : Frequency freq : Frequency
volt : Voltage volt : Voltage
ovc : Overcurrent detection status ovc : Overcurrent detection status
(+: Overcurrent, - Normal) (+: Overcurrent, - Normal)

7) PWM data 7) PWM data


PWM# : PWM channel number PWM# : PWM channel number
actcur : Actual milli-amp for flow control proportional actcur : Actual milli-amp for flow control proportional
valve valve
tgtcur : Target milli-amp for flow control proportional tgtcur : Target milli-amp for flow control proportional
valve valve
duty : Duty duty : Duty
freq : Frequency freq : Frequency
volt : Voltage volt : Voltage
ovc : Overcurrent detection status ovc : Overcurrent detection status
(+: Overcurrent, - Normal) (+: Overcurrent, - Normal)

8) Frequency and communication 8) Frequency and communication


FreqIn : Frequency input FreqIn : Frequency input
CAN : CAN reception state CAN : CAN reception state
UART : UART reception state UART : UART reception state
RS232 : RS232C communication state RS232 : RS232C communication state
-5- : * -5- : *
-6- : * -6- : *
-7- : * -7- : *
Input /output state ( = Receiving) Input /output state ( = Receiving)

CAN CAN
1 1
2 2
3 3
1 Computer S reception state 1 Computer S reception state
2 Computer B reception state 2 Computer B reception state
3 ECM reception state 3 ECM reception state

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-93 4001-93
D) H / W-B D) H / W-B
1) Computer B digital input / output 1) Computer B digital input / output

CHK H /W -B 1 DI1 CH K H /W -B 1 DI1


DO1 DI2 DO1 DI2
DO2 DI3 DO2 DI3
DO3 DI4 DO3 DI4

Input /output state ( = OFF, = ON ) Input /output state ( = OFF, = ON )


DO1 DO2 DO3 DO1 DO2 DO3

*
1
* * *
1
* *
2
* * 2
* *
3
* * 3
* *
* * * *
DI1 DI2 DI3 DI1 DI2 DI3
4 * 4 *
5
* 5
*
6
* * 6
* *
7
*8 * 7
*8 *
* *
IDI4 IDI4
* *
* *
* *
* *
1 Solenoid; lever lock 6 Switch; Interference (Temporary release) 1 Solenoid; lever lock 6 Switch; Interference (Temporary release)
2 Rotating light and bucket lock 7 Switch; Lifting magnet mode 2 Rotating light and bucket lock 7 Switch; Lifting magnet mode
3 Buzzer; Crane 8 Switch; Interference (Shut-off release) 3 Buzzer; Crane 8 Switch; Interference (Shut-off release)
4 Switch; Crane Mode 4 Switch; Crane Mode
5 Switch; Crane (Display switching) 5 Switch; Crane (Display switching)

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-94 4001-94

2) Digital output / output monitor 2) Digital output / output monitor

CHK H /W -B 2 -4- C HK H /W -B 2 -4-


DO1 DOM1 DO1 DOM1
DO2 DOM2 DO2 DOM2
DO3 DOM3 DO3 DOM3

Input /output state ( = OFF, = ON ) Input /output state ( = OFF, = ON )


DO1 DO2 DO3 DO1 DO2 DO3

1
* * * 1
* * *
2
* * 2
* *
3
* * 3
* *
* * * *
-4- DOM1 DOM2 -4- DOM1 DOM2

* *1 * * *1 *
* 2
* * 2
*
* 3
* * 3
*
* * * *
DOM3 DOM3

* *
* *
* *
* *
1 Solenoid; Lever lock 1 Solenoid; Lever lock
2 Rotating light and bucket lock 2 Rotating light and bucket lock
3 Buzzer; Crane 3 Buzzer; Crane

3) Potentio-meter voltage 3) Potentio-meter voltage


Pot1 : Sensor; Angle boom Pot1 : Sensor; Angle boom
CHK H /W -B 3 Pot4 0000 V Pot2 : Sensor; Angle arm C HK H /W -B 3 Pot4 0000 V Pot2 : Sensor; Angle arm
Pot3 : Sensor; Angle offset Pot3 : Sensor; Angle offset
Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V
Pot4 : Sensor; Pressure bottom Pot4 : Sensor; Pressure bottom
Pot2 0000 V Pot6 0000 V Pot5 : Sensor; Pressure rod Pot2 0000 V Pot6 0000 V Pot5 : Sensor; Pressure rod
Pot3 0000 V Pot7 0000 V Pot6 : * Pot3 0000 V Pot7 0000 V Pot6 : *
Pot7 : * Pot7 : *

4) Potentio-meter and sensor voltage (resistance) 4) Potentio-meter and sensor voltage (resistance)
Pot8 : * Pot8 : *
CHK H /W -B 4 Sn1 0000 V Pot9 : * C HK H /W -B 4 Sn1 0000 V Pot9 : *
Pot10 : * Pot10 : *
Pot8 0000 V Sn2 0000 V Pot8 0000 V Sn2 0000 V
Sn1 : * Sn1 : *
Pot9 0000 V Sn1 0000 Ω Sn2 : * Pot9 0000 V Sn1 0000 Ω Sn2 : *
Pot10 0000 V Sn2 0000 Ω Sn1 : * Pot10 0000 V Sn2 0000 Ω Sn1 : *
Sn2 : * Sn2 : *

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-95 4001-95
5) PWM data 5) PWM data
PWM# : PWM channel number PWM# : PWM channel number
actcur : Actual milli-amp for boom propor tional actcur : Actual milli-amp for boom propor tional
valve valve
tgtcur : Target milli-amp for boom propor tional tgtcur : Target milli-amp for boom propor tional
valve valve
duty : Duty duty : Duty
freq : Frequency freq : Frequency
volt : Voltage volt : Voltage
ovc : Overcurrent detection status ovc : Overcurrent detection status
(+: Overcurrent, - Normal) (+: Overcurrent, - Normal)

6) PWM data 6) PWM data


PWM# : PWM channel number PWM# : PWM channel number
actcur : Actual milli-amp for offset proportional actcur : Actual milli-amp for offset proportional
valve valve
tgtcur : Target milli-amp for offset proportional tgtcur : Target milli-amp for offset proportional
valve valve
duty : Duty duty : Duty
freq : Frequency freq : Frequency
volt : Voltage volt : Voltage
ovc : Overcurrent detection status ovc : Overcurrent detection status
(+: Overcurrent, - Normal) (+: Overcurrent, - Normal)

7) PWM data 7) PWM data


PWM# : PWM channel number PWM# : PWM channel number
actcur : Actual milli-amp for arm proportional valve actcur : Actual milli-amp for arm proportional valve
tgtcur : Target milli-amp for arm proportional valve tgtcur : Target milli-amp for arm proportional valve
duty : Duty duty : Duty
freq : Frequency freq : Frequency
volt : Voltage volt : Voltage
ovc : Overcurrent detection status ovc : Overcurrent detection status
(+: Overcurrent, - Normal) (+: Overcurrent, - Normal)

8) Frequency and communication 8) Frequency and communication


FreqIn : Frequency input FreqIn : Frequency input
CAN : CAN reception state CAN : CAN reception state
UART : UART communication state UART : UART communication state
RS232 : RS232C communication state RS232 : RS232C communication state
-5- : * -5- : *
-6- : * -6- : *
-7- : * -7- : *

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-96 4001-96

E) H / W-M E) H / W-M
1) Monitor 1) Monitor

CHK H /W -M 1 DI1 CH K H /W -M 1 DI1


DO1 DI2 DO1 DI2
DO2 DI3 DO2 DI3
DO3 DI4 DO3 DI4

Input /output state ( = OFF, = ON ) Input /output state ( = OFF, = ON )


DO1 DO2 DO3 DO1 DO2 DO3
1 * * 1 * *
2 * * 2 * *
3 * * 3 * *
4 5 * 4 5 *
DI1 DI2 DI1 DI2
6 10 6 10
7 11 7 11
8 12 8 12
9 13 9 13
DI3 IDI4 DI3 IDI4
*
14 * *
14 *
15 * 15 *
16 * 16 *
* *
1 Working light 9 Switch; Horn volume select 1 Working light 9 Switch; Horn volume select
2 Motor Washer 10 Switch; Breaker select 2 Motor Washer 10 Switch; Breaker select
3 Wiper CNT 11 Switch; Limit Front window 3 Wiper CNT 11 Switch; Limit Front window
4 Wiper INT 12 Switch; Wiper 4 Wiper INT 12 Switch; Wiper
5 Relay; horn volume switchover 13 Switch; Washer 5 Relay; horn volume switchover 13 Switch; Washer
6 Switch; Working light 14 Switch; Reserve 6 Switch; Working light 14 Switch; Reserve
7 Switch ; Travel high-speed select 15 Switch; 2 pumps flow 7 Switch ; Travel high-speed select 15 Switch; 2 pumps flow
8 Switch; Auto idle select 16 Switch; Crusher select 8 Switch; Auto idle select 16 Switch; Crusher select

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-97 4001-97

2. DIAG (trouble diagnosis) Screen 2. DIAG (trouble diagnosis) Screen


1. In diagnosis mode, you can check from the contents for the trouble currently occurring to a log 1. In diagnosis mode, you can check from the contents for the trouble currently occurring to a log
of trouble that has occurred in the past. of trouble that has occurred in the past.

1 Status occurence count 4 Diagnostic trouble code 1 Status occurence count 4 Diagnostic trouble code
2 Initial occurence time 5 Cursor movement 2 Initial occurence time 5 Cursor movement
3 Final occurence time 3 Final occurence time
• In "DTC-1" through "DTC-4", the data is displayed in order from the most recently occurring trouble • In "DTC-1" through "DTC-4", the data is displayed in order from the most recently occurring trouble
code. code.
• The cursor is moved with the wiper switch and auto idle switch. • The cursor is moved with the wiper switch and auto idle switch.
(The cursor moves between "DTC-1" and "DTC-4"). (The cursor moves between "DTC-1" and "DTC-4").
* There is no "section" in diagnosis mode. * There is no "section" in diagnosis mode.
• The information for the trouble code for the location under the cursor is displayed in the order "ST/OC", • The information for the trouble code for the location under the cursor is displayed in the order "ST/OC",
"1st", "Last". "1st", "Last".
• The mark displayed at the left most of "ST/OC" shows whether or not the trouble is currently • The mark displayed at the left most of "ST/OC" shows whether or not the trouble is currently
occurring. occurring.
• The black circle means the trouble is currently occurring. • The black circle means the trouble is currently occurring.
• The clear circle means the trouble is not occurring now, but has occurred in the past. • The clear circle means the trouble is not occurring now, but has occurred in the past.
• "1st" indicates the time at which this trouble occurred the first time and "last" indicates the time at which • "1st" indicates the time at which this trouble occurred the first time and "last" indicates the time at which
this trouble occurred the last time. this trouble occurred the last time.
2. For details on "diagnostic trouble codes" that can be read in diagnosis mode and their contents, see the 2. For details on "diagnostic trouble codes" that can be read in diagnosis mode and their contents, see the
"Main Unit Diagnostic Trouble Code List" "Main Unit Diagnostic Trouble Code List"

A) Screen A) Screen
(C) (C)

D I AG MAI N 1 DTC1 7002 4 D I AG MAI N 1 DTC1 7002 4

1 St/Oc 005 DTC2 0238 1 St/Oc 005 DTC2 0238


2 1st 0010 hr DTC3 ---- 2 1st 0010 hr DTC3 ----
3 Last 0901 hr DTC4 ---- 3 Last 0901 hr DTC4 ----

1. Displays the status at the cursor(C) and the occurrence count. 1. Displays the status at the cursor(C) and the occurrence count.
...7002 error now occuring / trouble has occured 5 times in the past. ...7002 error now occuring / trouble has occured 5 times in the past.
St/Oc 005 Status St/Oc 005 Status
005 Occurence count 005 Occurence count
[Status] [Status]
• Displays whether the diagnostic trouble code under the cursor is current or from the past. • Displays whether the diagnostic trouble code under the cursor is current or from the past.
• For , the trouble is current or continuing. • For , the trouble is current or continuing.
• For , the status is normal or recovered. • For , the status is normal or recovered.
(The trouble is not occurring now, but has occurred in the past). (The trouble is not occurring now, but has occurred in the past).
[Occurrence count] [Occurrence count]
• The number of times that diagnostic trouble code under the cursor has occurred • The number of times that diagnostic trouble code under the cursor has occurred

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-98 4001-98
2. Displays the time at which the trouble under the cursor first occurred 2. Displays the time at which the trouble under the cursor first occurred

1st 0010 ...Occurred first at 10 hours 1st 0010 ...Occurred first at 10 hours
hr hr
3. Displays the time at which the trouble under the cursor last occurred 3. Displays the time at which the trouble under the cursor last occurred

Last 0901 ...Occurred last at 901 hours Last 0901 ...Occurred last at 901 hours
hr hr
4. Diagnostic trouble code 4. Diagnostic trouble code
The troubles are sorted with the last one to occur at the top of the list. The troubles are sorted with the last one to occur at the top of the list.
The diagnostic trouble code under the cursor is displayed in (1) - (3). The diagnostic trouble code under the cursor is displayed in (1) - (3).
...7002 (faulty N1 pressure sensor) ...7002 (faulty N1 pressure sensor)
DTC1 7002 DTC1 7002
...0238 (Boost pressure sensor abnormally high voltage) ...0238 (Boost pressure sensor abnormally high voltage)
DTC2 0238 DTC2 0238
For details on diagnostic triuble code, see the Main Unit Diagnostic Trouble Code For details on diagnostic triuble code, see the Main Unit Diagnostic Trouble Code
DTC3 ---- DTC3 ----
List. List.
DTC4 ---- DTC4 ----
Maximum display count Maximum display count
4 codes per page X 16 pages = 64 diagnostic trouble codes are displayed. From the 65th code onward, the 4 codes per page X 16 pages = 64 diagnostic trouble codes are displayed. From the 65th code onward, the
oldest code is erased. However, even though these codes are not displayed, the data is retained. oldest code is erased. However, even though these codes are not displayed, the data is retained.

B) Operation B) Operation
1) Cursor up/down: 1) Cursor up/down:
Up operation ... wiper switch Up operation ... wiper switch
1 Down operation ... auto idle switch 1 Down operation ... auto idle switch
2) Page forward / back: 2) Page forward / back:
Forward operation ... light switch Forward operation ... light switch
Back operation ... washer switch Back operation ... washer switch
2 2

C) Reset C) Reset
If the washer switch and the light switch are held down for 10 seconds, the trouble log is reset. If the washer switch and the light switch are held down for 10 seconds, the trouble log is reset.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-99 4001-99

3. HR (usage log) Screen List 3. HR (usage log) Screen List


In HR mode, operation times for mechanical parts, electrical parts, etc., operation counts for switches In HR mode, operation times for mechanical parts, electrical parts, etc., operation counts for switches
and solenoids, as well as pressure distributions, etc. can be displayed. and solenoids, as well as pressure distributions, etc. can be displayed.
Section Section
Select switch Select switch
Page (-) Page (-)
Page (+) Page (+)

1 Section 2 Page 1 Section 2 Page

A) MAIN A) MAIN
1) Main unit operating time 1) Main unit operating time
KeyOn : Computer A power supply ON time KeyOn : Computer A power supply ON time
HR MA I N 1 Upr 0000 hr EngOn : Alternator power generating time HR MA I N 1 Upr 0000 hr EngOn : Alternator power generating time
Work : Machine operating time Work : Machine operating time
KeyOn 0000 hr Swg 0000 hr KeyOn 0000 hr Swg 0000 hr
(Upper ON or travel ON) (Upper ON or travel ON)
EngOn 0000 hr Trv 0000 hr Upr : Upper operating time EngOn 0000 hr Trv 0000 hr Upr : Upper operating time
Work 0000 TrSolo 0000 Swg : Swing operating time Work 0000 TrSolo 0000 Swg : Swing operating time
hr hr hr hr
Trv : Travel operating time Trv : Travel operating time
TrSolo : Travel single operation time TrSolo : Travel single operation time

2) Electrical part operating time 2) Electrical part operating time


WpInt : Wiper (intermittent) operating time WpInt : Wiper (intermittent) operating time
HR MA I N 2 WLight 0000 hr WpCnt : Wiper (continuous) operating time HR MA I N 2 WLight 0000 hr WpCnt : Wiper (continuous) operating time
Wsh : Washer operating time Wsh : Washer operating time
WpInt 0000 hr HornLo 0000 hr WpInt 0000 hr HornLo 0000 hr
WLight : Working light ON time WLight : Working light ON time
WpCnt 0000 hr DrOpn 0000 hr HornLo : Horn volume low time WpCnt 0000 hr DrOpn 0000 hr HornLo : Horn volume low time
Wsh 0000 hr WinOpn 0000 hr DrOpn : * Wsh 0000 hr WinOpn 0000 hr DrOpn : *
WinOpn : Front window open time WinOpn : Front window open time

3) Idle time 3) Idle time


1 : Auto idle time 1 : Auto idle time
HR MA I N 3 4 0000 hr 2 : One-touch idle time HR MA I N 3 4 0000 hr 2 : One-touch idle time
3 : Boosted pressure time 3 : Boosted pressure time
1 0000 hr 5 0000 hr 1 0000 hr 5 0000 hr
4 : Low-speed travel time 4 : Low-speed travel time
2 0000 hr 6 0000 hr 5 : High-speed travel time 2 0000 hr 6 0000 hr 5 : High-speed travel time
3 0000 hr 7 0000 hr 6 : * 3 0000 hr 7 0000 hr 6 : *
7 : * 7 : *

4) Pressure switch operation count 4) Pressure switch operation count


1 : Upper pressure sensor (ON count X 1000) 1 : Upper pressure sensor (ON count X 1000)
HR MA I N 4 4 0000 times 2 : Swing pressure sensor (ON count X 1000) HR MA I N 4 4 0000 times 2 : Swing pressure sensor (ON count X 1000)
3 : Travel pressure sensor (ON count X 1000) 3 : Travel pressure sensor (ON count X 1000)
1 0000 times 5 0000 times 1 0000 times 5 0000 times
4 : Arm-in pressure switch (ON count X 1000) 4 : Arm-in pressure switch (ON count X 1000)
2 0000 times 6 0000 times 5 : 1st option pressure switch (ON count X 1000) 2 0000 times 6 0000 times 5 : 1st option pressure switch (ON count X 1000)
3 0000 times 7 0000 times 6 : 2nd option pressure switch (ON count X 1000) 3 0000 times 7 0000 times 6 : 2nd option pressure switch (ON count X 1000)
7 : * 7 : *

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-100 4001-100
5) Operation switch operation count 5) Operation switch operation count
1 : Key ON count X 10 1 : Key ON count X 10
HR MAI N 5 4 0000 times 2 : Engine start count X 10 HR MA I N 5 4 0000 times 2 : Engine start count X 10
3 : Front window open count X 10 3 : Front window open count X 10
1 0000 times 5 0000 times 1 0000 times 5 0000 times
4 : * 4 : *
2 0000 times 6 0000 times 5 : Boost solenoid ON count X 1000 2 0000 times 6 0000 times 5 : Boost solenoid ON count X 1000
3 0000 times 7 0000 times 6 : Swing brake solenoid ON count X 1000 3 0000 times 7 0000 times 6 : Swing brake solenoid ON count X 1000
7 : Power save solenoid ON count X 1000 7 : Power save solenoid ON count X 1000

6) Work mode 6) Work mode


1 : Mode usage time SP-hi 1 : Mode usage time SP-hi
HR MAI N 6 4 0000 hr 2 : Mode usage time SP-lo HR MA I N 6 4 0000 hr 2 : Mode usage time SP-lo
3 : Mode usage time H-hi 3 : Mode usage time H-hi
1 0000 hr 5 0000 hr 1 0000 hr 5 0000 hr
4 : Mode usage time H-lo 4 : Mode usage time H-lo
2 0000 hr 6 0000 hr 5 : Mode usage time A1-hi 2 0000 hr 6 0000 hr 5 : Mode usage time A1-hi
3 0000 hr 7 0000 hr 6 : Mode usage time A1-lo 3 0000 hr 7 0000 hr 6 : Mode usage time A1-lo
7 : Mode usage time (other than above) 7 : Mode usage time (other than above)

7) Breaker usage time 7) Breaker usage time


1 : Breaker 1 operation time 1 : Breaker 1 operation time
HR MAI N 7 4 0000 hr 2 : Breaker 2 operation time HR MA I N 7 4 0000 hr 2 : Breaker 2 operation time
3 : Breaker 3 operation time 3 : Breaker 3 operation time
1 0000 hr 5 0000 hr 1 0000 hr 5 0000 hr
4 : Breaker 4 operation time 4 : Breaker 4 operation time
2 0000 hr 6 0000 hr 5 : Breaker 5 operation time 2 0000 hr 6 0000 hr 5 : Breaker 5 operation time
3 0000 hr 7 0000 hr 6 : Breaker 1-5 operation time 3 0000 hr 7 0000 hr 6 : Breaker 1-5 operation time
7 : * 7 : *

8) Crusher usage time 8) Crusher usage time


1 : Crusher 1 operation time 1 : Crusher 1 operation time
HR MAI N 8 4 0000 hr 2 : Crusher 2 operation time HR MA I N 8 4 0000 hr 2 : Crusher 2 operation time
3 : Crusher 3 operation time 3 : Crusher 3 operation time
1 0000 hr 5 0000 hr 1 0000 hr 5 0000 hr
4 : Crusher 4 operation time 4 : Crusher 4 operation time
2 0000 hr 6 0000 hr 5 : Crusher 5 operation time 2 0000 hr 6 0000 hr 5 : Crusher 5 operation time
3 0000 hr 7 0000 hr 6 : Crusher 1-5 operation time 3 0000 hr 7 0000 hr 6 : Crusher 1-5 operation time
7 : * 7 : *

9) P1 pressure (P) distribution 9) P1 pressure (P) distribution


1 : P < 10 MPa Time 1 : P < 10 MPa Time
HR MAI N 9 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time HR MA I N 9 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time
3 : 15 MPa ≤ P < 20 MPa Time 3 : 15 MPa ≤ P < 20 MPa Time
1 0000 hr 5 0000 hr 1 0000 hr 5 0000 hr
4 : 20 MPa ≤ P < 25 MPa Time 4 : 20 MPa ≤ P < 25 MPa Time
2 0000 hr 6 0000 hr 5 : 25 MPa ≤ P < 30 MPa Time 2 0000 hr 6 0000 hr 5 : 25 MPa ≤ P < 30 MPa Time
3 0000 hr 7 0000 hr 6 : 30 MPa ≤ P < 35 MPa Time 3 0000 hr 7 0000 hr 6 : 30 MPa ≤ P < 35 MPa Time
7 : 35 MPa ≤ P Time 7 : 35 MPa ≤ P Time

10) P2 pressure (P) distribution 10) P2 pressure (P) distribution


1 : P < 10 MPa Time 1 : P < 10 MPa Time
HR MAI N 10 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time HR MA I N 10 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time
3 : 15 MPa ≤ P < 20 MPa Time 3 : 15 MPa ≤ P < 20 MPa Time
1 0000 hr 5 0000 hr 1 0000 hr 5 0000 hr
4 : 20 MPa ≤ P < 25 MPa Time 4 : 20 MPa ≤ P < 25 MPa Time
2 0000 hr 6 0000 hr 5 : 25 MPa ≤ P < 30 MPa Time 2 0000 hr 6 0000 hr 5 : 25 MPa ≤ P < 30 MPa Time
3 0000 hr 7 0000 hr 6 : 30 MPa ≤ P < 35 MPa Time 3 0000 hr 7 0000 hr 6 : 30 MPa ≤ P < 35 MPa Time
7 : 35 MPa ≤ P Time 7 : 35 MPa ≤ P Time

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-101 4001-101
11) N1 pressure (P) distribution 11) N1 pressure (P) distribution
1 : P < 10 MPa Time 1 : P < 10 MPa Time
HR MA I N 11 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time HR MA I N 11 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time
3 : 15 MPa ≤ P < 20 MPa Time 3 : 15 MPa ≤ P < 20 MPa Time
1 0000 hr 5 0000 hr 1 0000 hr 5 0000 hr
4 : 20 MPa ≤ P < 25 MPa Time 4 : 20 MPa ≤ P < 25 MPa Time
2 0000 hr 6 0000 hr 5 : 25 MPa ≤ P < 30 MPa Time 2 0000 hr 6 0000 hr 5 : 25 MPa ≤ P < 30 MPa Time
3 0000 hr 7 0000 hr 6 : 30 MPa ≤ P < 35 MPa Time 3 0000 hr 7 0000 hr 6 : 30 MPa ≤ P < 35 MPa Time
7 : 35 MPa ≤ P Time 7 : 35 MPa ≤ P Time

12) N2 pressure (P) distribution 12) N2 pressure (P) distribution


1 : P < 10 MPa Time 1 : P < 10 MPa Time
HR MA I N 12 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time HR MA I N 12 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time
3 : 15 MPa ≤ P < 20 MPa Time 3 : 15 MPa ≤ P < 20 MPa Time
1 0000 hr 5 0000 hr 1 0000 hr 5 0000 hr
4 : 20 MPa ≤ P < 25 MPa Time 4 : 20 MPa ≤ P < 25 MPa Time
2 0000 hr 6 0000 hr 5 : 25 MPa ≤ P < 30 MPa Time 2 0000 hr 6 0000 hr 5 : 25 MPa ≤ P < 30 MPa Time
3 0000 hr 7 0000 hr 6 : 30 MPa ≤ P < 35 MPa Time 3 0000 hr 7 0000 hr 6 : 30 MPa ≤ P < 35 MPa Time
7 : 35 MPa ≤ P Time 7 : 35 MPa ≤ P Time

13) P1 + P2 pressure (P) distribution 13) P1 + P2 pressure (P) distribution


1 : P < 20 MPa Time 1 : P < 20 MPa Time
HR MA I N 13 4 0000 2 : 20 MPa ≤ P < 30 MPa Time HR M AI N 13 4 0000 2 : 20 MPa ≤ P < 30 MPa Time
hr hr
3 : 30 MPa ≤ P < 40 MPa Time 3 : 30 MPa ≤ P < 40 MPa Time
1 0000 hr 5 0000 hr 4 : 40 MPa ≤ P < 50 MPa Time 1 0000 hr 5 0000 hr 4 : 40 MPa ≤ P < 50 MPa Time
2 0000 hr 6 0000 hr 5 : 50 MPa ≤ P < 60 MPa Time 2 0000 hr 6 0000 hr 5 : 50 MPa ≤ P < 60 MPa Time
6 : 60 MPa ≤ P < 70 MPa Time 6 : 60 MPa ≤ P < 70 MPa Time
3 0000 hr 7 0000 hr 3 0000 hr 7 0000 hr
7 : 70 MPa ≤ P Time 7 : 70 MPa ≤ P Time

14) Oil temperature (T) distribution 14) Oil temperature (T) distribution
1 : T< 45°C Time (bar graph 1st and 2nd gradation) 1 : T< 45°C Time (bar graph 1st and 2nd gradation)
2 : 45°C ≤ T< 60°C Time (bar graph 3rd gradation) 2 : 45°C ≤ T< 60°C Time (bar graph 3rd gradation)
HR MA I N 14 4 0000 hr HR M AI N 14 4 0000 hr
3 : 60°C ≤ T < 80°C Time (bar graph 4th gradation) 3 : 60°C ≤ T < 80°C Time (bar graph 4th gradation)
1 0000 hr 5 0000 hr 4 : 80°C ≤ T < 88°C Time (bar graph 5th gradation) 1 0000 hr 5 0000 hr 4 : 80°C ≤ T < 88°C Time (bar graph 5th gradation)
2 0000 hr 6 0000 hr 5 : 88 °C ≤ T < 95 °C Time (bar graph 6th gradation) 2 0000 hr 6 0000 hr 5 : 88 °C ≤ T < 95 °C Time (bar graph 6th gradation)
6 : 95 °C ≤ T < 98 °C Time (bar graph 7th gradation) 6 : 95 °C ≤ T < 98 °C Time (bar graph 7th gradation)
3 0000 hr 7 0000 hr 3 0000 hr 7 0000 hr
7 : 98 °C ≤ T Time (bar graph 8th gradation) 7 : 98 °C ≤ T Time (bar graph 8th gradation)

B) ENG B) ENG
1) Oil temperature / coolant temperature / pressure maximum values 1) Oil temperature / coolant temperature / pressure maximum values
(Measured starting 10 minutes after engine started) (Measured starting 10 minutes after engine started)
Coolnt : Radiator coolant temperature Coolnt : Radiator coolant temperature
HR EN G 1 Air 0000 ˚C HydOil : Hydraulic oil maximum temperature HR EN G 1 Air 0000 ˚C HydOil : Hydraulic oil maximum temperature
FuelT : Fuel maximum temperature FuelT : Fuel maximum temperature
Coolnt 0000 ˚C BstT 0000 ˚C Air : Suction air maximum temperature Coolnt 0000 ˚C BstT 0000 ˚C Air : Suction air maximum temperature
HydOil 0000 ˚C BstP 0000 kPa BstT : Boost maximum temperature HydOil 0000 ˚C BstP 0000 kPa BstT : Boost maximum temperature
BstP : Boost maximum pressure BstP : Boost maximum pressure
FuelT 0000 ˚C EngOil 0000 kPa FuelT 0000 ˚C EngOil 0000 kPa
EngOil : Engine oil minimum pressure EngOil : Engine oil minimum pressure

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-102 4001-102
2) Engine actual speed (S) distribution 2) Engine actual speed (S) distribution
1 : S < 1025 min-1 Time 1 : S < 1025 min-1 Time
HR ENG 2 4 0000 2 : 1025 min-1 ≤ S < 1225 min-1 Time HR EN G 2 4 0000 2 : 1025 min-1 ≤ S < 1225 min-1 Time
hr hr
3 : 1225 min-1 ≤ S < 1425 min-1 Time 3 : 1225 min-1 ≤ S < 1425 min-1 Time
1 0000 hr 5 0000 hr 4 : 1425 min-1 ≤ S < 1625 min-1 Time 1 0000 hr 5 0000 hr 4 : 1425 min-1 ≤ S < 1625 min-1 Time
2 0000 hr 6 0000 hr 5 : 1625 min-1 ≤ S < 1825 min-1 Time 2 0000 hr 6 0000 hr 5 : 1625 min-1 ≤ S < 1825 min-1 Time
6 : 1825 min-1 ≤ S < 2025 min-1 Time 6 : 1825 min-1 ≤ S < 2025 min-1 Time
3 0000 hr 7 0000 hr 3 0000 hr 7 0000 hr
7 : 2025 min-1 ≤ S Time 7 : 2025 min-1 ≤ S Time

3) Coolant temperature (T) distribution 3) Coolant temperature (T) distribution


1 : T < 77 °C Time (bar graph 1st and 2nd gradation) 1 : T < 77 °C Time (bar graph 1st and 2nd gradation)
HR ENG 3 4 0000 hr 2 : 77 °C ≤ T < 82 °C Time (bar graph 3rd gradation) HR E NG 3 4 0000 hr 2 : 77 °C ≤ T < 82 °C Time (bar graph 3rd gradation)
1 0000 hr 5 0000 hr 3 : 82 °C ≤ T < 97 °C Time (bar graph 4th gradation) 1 0000 hr 5 0000 hr 3 : 82 °C ≤ T < 97 °C Time (bar graph 4th gradation)
4 : 97 °C ≤ T < 100 °C Time (bar graph 5th gradation) 4 : 97 °C ≤ T < 100 °C Time (bar graph 5th gradation)
2 0000 hr 6 0000 hr 2 0000 hr 6 0000 hr
5 : 100 °C ≤ T < 103 °C Time (bar graph 6th gradation) 5 : 100 °C ≤ T < 103 °C Time (bar graph 6th gradation)
3 0000 hr 7 0000 hr 6 : 103 °C ≤ T < 105 °C Time (bar graph 7th gradation) 3 0000 hr 7 0000 hr 6 : 103 °C ≤ T < 105 °C Time (bar graph 7th gradation)
7 : 105 °C ≤ T Time (bar graph 8th gradation) 7 : 105 °C ≤ T Time (bar graph 8th gradation)

4) Fuel temperature (T) distribution 4) Fuel temperature (T) distribution


1 : T < 40 °C Time 1 : T < 40 °C Time
HR ENG 4 4 0000 hr 2 : 40 °C ≤ T < 50 °C Time HR EN G 4 4 0000 hr 2 : 40 °C ≤ T < 50 °C Time
1 0000 hr 5 0000 hr 3 : 50 °C ≤ T < 60 °C Time 1 0000 hr 5 0000 hr 3 : 50 °C ≤ T < 60 °C Time
4 : 60 °C ≤ T < 70 °C Time 4 : 60 °C ≤ T < 70 °C Time
2 0000 hr 6 0000 hr 2 0000 hr 6 0000 hr
5 : 70 °C ≤ T < 80 °C Time 5 : 70 °C ≤ T < 80 °C Time
3 0000 hr 7 0000 hr 6 : 80 °C ≤ T < 90 °C Time 3 0000 hr 7 0000 hr 6 : 80 °C ≤ T < 90 °C Time
7 : 90 °C ≤ T Time 7 : 90 °C ≤ T Time

5) Suction air temperature (T) distribution 5) Suction air temperature (T) distribution
1 : T < -20 °C Time 1 : T < -20 °C Time
HR ENG 5 4 0000 hr 2 : -20 °C ≤ T < 0 °C Time HR EN G 5 4 0000 hr 2 : -20 °C ≤ T < 0 °C Time
1 0000 hr 5 0000 hr 3 : 0 °C ≤ T < 15 °C Time 1 0000 hr 5 0000 hr 3 : 0 °C ≤ T < 15 °C Time
4 : 15 °C ≤ T < 30 °C Time 4 : 15 °C ≤ T < 30 °C Time
2 0000 hr 6 0000 hr 2 0000 hr 6 0000 hr
5 : 30 °C ≤ T < 45 °C Time 5 : 30 °C ≤ T < 45 °C Time
3 0000 hr 7 0000 hr 6 : 45 °C ≤ T < 60 °C Time 3 0000 hr 7 0000 hr 6 : 45 °C ≤ T < 60 °C Time
7 : 60 °C ≤ T Time 7 : 60 °C ≤ T Time

6) Boost temperature (T) distribution 6) Boost temperature (T) distribution


1 : T < 50 °C Time 1 : T < 50 °C Time
HR ENG 6 4 0000 hr 2 : 50 °C ≤ T < 80 °C Time HR E NG 6 4 0000 hr 2 : 50 °C ≤ T < 80 °C Time
1 0000 hr 5 0000 hr 3 : 80 °C ≤ T < 110 °C Time 1 0000 hr 5 0000 hr 3 : 80 °C ≤ T < 110 °C Time
4 : 110 °C ≤ T < 140 °C Time 4 : 110 °C ≤ T < 140 °C Time
2 0000 hr 6 0000 hr 2 0000 hr 6 0000 hr
5 : 140 °C ≤ T < 170 °C Time 5 : 140 °C ≤ T < 170 °C Time
3 0000 hr 7 0000 hr 6 : 170 °C ≤ T < 200 °C Time 3 0000 hr 7 0000 hr 6 : 170 °C ≤ T < 200 °C Time
7 : 200 °C ≤ T Time 7 : 200 °C ≤ T Time

7) Atmospheric pressure (P) distribution 7) Atmospheric pressure (P) distribution


1 : P < 600 hPa Time 1 : P < 600 hPa Time
HR ENG 7 4 0000 hr 2 : 600 hPa ≤ P < 690 hPa Time HR EN G 7 4 0000 hr 2 : 600 hPa ≤ P < 690 hPa Time
1 0000 hr 5 0000 hr 3 : 690 hPa ≤ P < 780 hPa Time 1 0000 hr 5 0000 hr 3 : 690 hPa ≤ P < 780 hPa Time
4 : 780 hPa ≤ P < 870 hPa Time 4 : 780 hPa ≤ P < 870 hPa Time
2 0000 hr 6 0000 hr 2 0000 hr 6 0000 hr
5 : 870 hPa ≤ P < 960 hPa Time 5 : 870 hPa ≤ P < 960 hPa Time
3 0000 hr 7 0000 hr 6 : 960 hPa ≤ P < 1050 hPa Time 3 0000 hr 7 0000 hr 6 : 960 hPa ≤ P < 1050 hPa Time
7 : 1050 hPa ≤ P Time 7 : 1050 hPa ≤ P Time

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-103 4001-103
8) Engine oil pressure (P) distribution 8) Engine oil pressure (P) distribution
1 : P < 0 kPa Time 1 : P < 0 kPa Time
HR ENG 8 4 0000 hr 2 : 0 kPa ≤ P < 150 kPa Time HR ENG 8 4 0000 hr 2 : 0 kPa ≤ P < 150 kPa Time
1 0000 hr 5 0000 hr 3 : 150 kPa ≤ P < 300 kPa Time 1 0000 hr 5 0000 hr 3 : 150 kPa ≤ P < 300 kPa Time
4 : 300 kPa ≤ P < 450 kPa Time 4 : 300 kPa ≤ P < 450 kPa Time
2 0000 hr 6 0000 hr 2 0000 hr 6 0000 hr
5 : 450 kPa ≤ P < 600 kPa Time 5 : 450 kPa ≤ P < 600 kPa Time
3 0000 hr 7 0000 hr 6 : 600 kPa ≤ P < 750 kPa Time 3 0000 hr 7 0000 hr 6 : 600 kPa ≤ P < 750 kPa Time
7 : 750 kPa ≤ P Time 7 : 750 kPa ≤ P Time

9) Boost pressure (P) distribution 9) Boost pressure (P) distribution


1 : P < 150 kPa Time 1 : P < 150 kPa Time
HR EN G 9 4 0000 hr 2 : 150 kPa ≤ P < 180 kPa Time HR E NG 9 4 0000 hr 2 : 150 kPa ≤ P < 180 kPa Time
1 0000 hr 5 0000 hr 3 : 180 kPa ≤ P < 210 kPa Time 1 0000 hr 5 0000 hr 3 : 180 kPa ≤ P < 210 kPa Time
4 : 210 kPa ≤ P < 240 kPa Time 4 : 210 kPa ≤ P < 240 kPa Time
2 0000 hr 6 0000 hr 2 0000 hr 6 0000 hr
5 : 240 kPa ≤ P < 270 kPa Time 5 : 240 kPa ≤ P < 270 kPa Time
3 0000 hr 7 0000 hr 6 : 270 kPa ≤ P < 300 kPa Time 3 0000 hr 7 0000 hr 6 : 270 kPa ≤ P < 300 kPa Time
7 : 300 kPa ≤ P Time 7 : 300 kPa ≤ P Time

10) Load ratio (R) distribution 10) Load ratio (R) distribution
1 : R < 30 % Time 1 : R < 30 % Time
HR EN G 10 4 0000 hr 2 : 30 % ≤ R < 40 % Time HR E NG 10 4 0000 hr 2 : 30 % ≤ R < 40 % Time
1 0000 hr 5 0000 hr 3 : 40 % ≤ R < 50 % Time 1 0000 hr 5 0000 hr 3 : 40 % ≤ R < 50 % Time
4 : 50 % ≤ R < 60 % Time 4 : 50 % ≤ R < 60 % Time
2 0000 hr 6 0000 hr 2 0000 hr 6 0000 hr
5 : 60 % ≤ R < 70 % Time 5 : 60 % ≤ R < 70 % Time
3 0000 hr 7 0000 hr 6 : 70 % ≤ R < 80 % Time 3 0000 hr 7 0000 hr 6 : 70 % ≤ R < 80 % Time
7 : 80 % ≤ R Time 7 : 80 % ≤ R Time

11) Load ratio (R) distribution for SP mode 11) Load ratio (R) distribution for SP mode
1 : R < 30 % Time 1 : R < 30 % Time
HR EN G 11 4 0000 hr 2 : 30 % ≤ R < 40 % Time HR EN G 11 4 0000 hr 2 : 30 % ≤ R < 40 % Time
1 0000 hr 5 0000 hr 3 : 40 % ≤ R < 50 % Time 1 0000 hr 5 0000 hr 3 : 40 % ≤ R < 50 % Time
4 : 50 % ≤ R < 60 % Time 4 : 50 % ≤ R < 60 % Time
2 0000 hr 6 0000 hr 2 0000 hr 6 0000 hr
5 : 60 % ≤ R < 70 % Time 5 : 60 % ≤ R < 70 % Time
3 0000 hr 7 0000 hr 6 : 70 % ≤ R < 80 % Time 3 0000 hr 7 0000 hr 6 : 70 % ≤ R < 80 % Time
7 : 80 % ≤ R Time 7 : 80 % ≤ R Time

12) Load ratio (R) distribution for H mode 12) Load ratio (R) distribution for H mode
1 : R < 30 % Time 1 : R < 30 % Time
HR EN G 12 4 0000 hr 2 : 30 % ≤ R < 40 % Time HR EN G 12 4 0000 hr 2 : 30 % ≤ R < 40 % Time
1 0000 hr 5 0000 hr 3 : 40 % ≤ R < 50 % Time 1 0000 hr 5 0000 hr 3 : 40 % ≤ R < 50 % Time
4 : 50 % ≤ R < 60 % Time 4 : 50 % ≤ R < 60 % Time
2 0000 hr 6 0000 hr 2 0000 hr 6 0000 hr
5 : 60 % ≤ R < 70 % Time 5 : 60 % ≤ R < 70 % Time
3 0000 hr 7 0000 hr 6 : 70 % ≤ R < 80 % Time 3 0000 hr 7 0000 hr 6 : 70 % ≤ R < 80 % Time
7 : 80 % ≤ R Time 7 : 80 % ≤ R Time

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-104 4001-104

4. CFG (setting change) Screen 4. CFG (setting change) Screen


The item where the cursor is located flashes. The item where the cursor is located flashes.
Can be changed Can be changed

The cursor appears if the auto The cursor appears if the auto
idle switch is held down idle switch is held down

• Hold down the auto idle switch for 1 second. The cursor is displayed and the value starts to flash. • Hold down the auto idle switch for 1 second. The cursor is displayed and the value starts to flash.
• The flashing value can be changed with the washer switch /working light switch. • The flashing value can be changed with the washer switch /working light switch.
• When the travel high-speed switch is pressed, value is finalized and the change is reflected in the actual • When the travel high-speed switch is pressed, value is finalized and the change is reflected in the actual
machine. machine.
• When the horn volume select switch is pressed, the change is cancelled • When the horn volume select switch is pressed, the change is cancelled

A) Operation A) Operation

Cursor Cursor

1) View mode (screen switching operation) 1) View mode (screen switching operation)
1) Switching to edit mode 1) Switching to edit mode
Hold down the auto idle switch for one second. Hold down the auto idle switch for one second.
The mode switches to edit mode and the cursor is The mode switches to edit mode and the cursor is
displayed. displayed.
2) Page forward / back: 2) Page forward / back:
1 1
Forward operation => light switch Forward operation => light switch
Back operation => washer switch Back operation => washer switch

2 2
2) Edit mode (setting change operation) 2) Edit mode (setting change operation)
1) Cursor up / down: 1) Cursor up / down:
Up operation => wiper switch Up operation => wiper switch
4 Down operation => auto idle switch 4 Down operation => auto idle switch
1 2) Numeric value increase / decrease: 1 2) Numeric value increase / decrease:
Increase value => light switch Increase value => light switch
3 Decrease value => washer switch 3 Decrease value => washer switch
3) Enter: Enters the set contents. 3) Enter: Enters the set contents.
4) Cancel: Cancels the set contents. 4) Cancel: Cancels the set contents.
When (3) and (4) is executed, this exits edit mode When (3) and (4) is executed, this exits edit mode
2 and shifts the mode to view mode (the cursor 2 and shifts the mode to view mode (the cursor
disappears). disappears).

3) Reset 3) Reset
If the washer switch and the light switch are held down for 10 seconds, the setting contents are reset and all If the washer switch and the light switch are held down for 10 seconds, the setting contents are reset and all
settings return to their default values. settings return to their default values.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-105 4001-105
B) Screen B) Screen
1) MAIN 1 1) MAIN 1

CFG M A IN 1 PrUp1 ++++ C FG M AI N 1 PrUp1 ++++


LowIdl 1000 min -1 PrUp2 ---- LowIdl 1000 min -1 PrUp2 ----
AtIdl1 0005 sec PwrAj 300 mA AtIdl1 0005 sec PwrAj 300 mA
AtIdl2 1200 -1 -7- AtIdl2 1200 -1 -7-
min min

Item name Explanation Setting range Default value Item name Explanation Setting range Default value
LowIdl Low idling speed Min speed to Auto-idle speed 1000 LowIdl Low idling speed Min speed to Auto-idle speed 1000
AtIdl1 Auto idling shift time 1 to 30 5 AtIdl1 Auto idling shift time 1 to 30 5
AtIdl2 Auto idling speed Low idling speed to 1500 1200 AtIdl2 Auto idling speed Low idling speed to 1500 1200
PrUp1 Auto pressure boost yes / no + : YES, - : NO + PrUp1 Auto pressure boost yes / no + : YES, - : NO +
PrUp2 Auto pressure boost for option line usage yes / no + : YES, - : NO - PrUp2 Auto pressure boost for option line usage yes / no + : YES, - : NO -
PwrAj Transient load minimum mili-amp 50 to 400 300 PwrAj Transient load minimum mili-amp 50 to 400 300
-7- High altitude correction milli-amp 0 to 250 0 -7- High altitude correction milli-amp 0 to 250 0
NOTE: PwrAj is the previous high altitude mode. NOTE: PwrAj is the previous high altitude mode.

2) MAIN 2 2) MAIN 2

CFG M A IN 2 CoolDn CF G MA I N 2 CoolDn


TrSpd ____ EPF ++++ TrSpd ____ EPF ++++

TrAlm1 ++++ Unit 0000 TrAlm1 ++++ Unit 0000


TrAlm2 0010 sec -7- TrAlm2 0010 sec -7-

Item name Explanation Setting range Default value Item name Explanation Setting range Default value
TrSpd Travel speed previous data held yes / no + : YES, - : NO - TrSpd Travel speed previous data held yes / no + : YES, - : NO -
TrAlm1 Travel alarm buzzing yes / no + : YES, - : NO + TrAlm1 Travel alarm buzzing yes / no + : YES, - : NO +
TrAlm2 Travel alarm automatic stop time 1 to 30 10 TrAlm2 Travel alarm automatic stop time 1 to 30 10
CoolDn CoolDn
EPF EPF (Engine Protection Feature) yes / no + : YES, - : NO + EPF EPF (Engine Protection Feature) yes / no + : YES, - : NO +
Unit Display unit + : YES, - : NO 0 Unit Display unit + : YES, - : NO 0
-7- -7-
* Display unit contents … MPa = (MPa,°C), PSI = (psi, °F), kgf/cm2 = (kgf/cm2, °C) * Display unit contents … MPa = (MPa,°C), PSI = (psi, °F), kgf/cm2 = (kgf/cm2, °C)

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-106 4001-106

3) MAIN 3 3) MAIN 3

CFG MAI N 3 MntMsg ++++ CF G MA I N 3 MntMsg ++++


Spd1 min -1 Cycle 0500 hr Spd1 min -1 Cycle 0500 hr
Spd2 -1 Remain 0500 Spd2 -1 Remain 0500
min hr min hr
OvLd 0000 MPa -7- ++++ OvLd 0000 MPa -7- ++++

Item name Explanation Setting range Default value Item name Explanation Setting range Default value
Spd1 Spd1
Spd2 Spd2
OvLd Pressure at which alarm starts OvLd Pressure at which alarm starts
MntMsg "SERVICE DUE" display yes / no + : YES, - : NO + MntMsg "SERVICE DUE" display yes / no + : YES, - : NO +
Cycle "SERVICE DUE" display range 0 to 5000 500 Cycle "SERVICE DUE" display range 0 to 5000 500
Remain Time until next "SERVICE DUE" display 0 to 5000 500 Remain Time until next "SERVICE DUE" display 0 to 5000 500
-7- New harness yes / no + : YES, - : NO + -7- New harness yes / no + : YES, - : NO +
* OvLd is an option for Europe. * OvLd is an option for Europe.
-7- is battery charge and engine emergency stop port substitution. -7- is battery charge and engine emergency stop port substitution.

4) A.INTF 1 4) A.INTF 1

Item name Explanation Setting range Default value Item name Explanation Setting range Default value
Front Front surface stop area compensation value Front Front surface stop area compensation value
Right Right surface stop compensation value Right Right surface stop compensation value
BkLen Bucket toe distance BkLen Bucket toe distance
BkWd Bucket width BkWd Bucket width
-5- N/A -5- N/A
-6- N/A -6- N/A
-7- N/A -7- N/A

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-107 4001-107

5. CAL (troubleshooting support) Screen 5. CAL (troubleshooting support) Screen

A) Operation A) Operation

Cursor Cursor

1) View mode (screen switching operation) 1) View mode (screen switching operation)
1) Switching to edit mode 1) Switching to edit mode
Hold down the auto idle switch for one second. Hold down the auto idle switch for one second.
The mode switches to edit mode and the cursor is The mode switches to edit mode and the cursor is
displayed. displayed.
2) Page forward / back: 2) Page forward / back:
1 Forward operation => light switch
1 Forward operation => light switch
Back operation => washer switch Back operation => washer switch

2 2

2) Edit mode (setting change operation) 2) Edit mode (setting change operation)
1) Cursor up / down: 1) Cursor up / down:
Up operation => wiper switch Up operation => wiper switch
4 Down operation => auto idle switch 4 Down operation => auto idle switch
2) Numeric value increase / decrease: 2) Numeric value increase / decrease:
1 Increase value => light switch 1 Increase value => light switch
3 Decrease value => washer switch 3 Decrease value => washer switch
3) Enter: Enters the set contents. 3) Enter: Enters the set contents.
4) Cancel: Cancels the set contents. 4) Cancel: Cancels the set contents.
Use the travel high-speed select switch or the Use the travel high-speed select switch or the
horn volume select switch to cancel. Exits edit horn volume select switch to cancel. Exits edit
2 mode and shifts the mode to view mode (the 2 mode and shifts the mode to view mode (the
cursor disappears). cursor disappears).

B) Screen B) Screen
1) Engine pump override 1 1) Engine pump override 1

Item name Explanation Setting range Default value Item name Explanation Setting range Default value
tEng Target engine speed 500 to max speed Low idling tEng Target engine speed 500 to max speed Low idling
tPower Target milli-amp for horsepower control proportional valve 50 to 740 50 tPower Target milli-amp for horsepower control proportional valve 50 to 740 50
tFlow Target milli-amp for flow control proportional valve 50 to 740 50 tFlow Target milli-amp for flow control proportional valve 50 to 740 50
P1 P1 pressure - - P1 P1 pressure - -
P2 P2 pressure - - P2 P2 pressure - -
N1 N1 pressure - - N1 N1 pressure - -
N2 N2 pressure - - N2 N2 pressure - -

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-108 4001-108
2) Engine pump override 2 2) Engine pump override 2

CAL MAIN 2 P1+P2 0 0 0 . 0 MPa C AL M AI N 2 P1+P2 0 0 0 . 0 MPa


-1 -1
tEng 1000 min Eng 0000 min-1 tEng 1000 min Eng 0000 min-1
tPower 0500 mA Power 0000 mA tPower 0500 mA Power 0000 mA
tFlow 0500 mA Flow 0000 mA tFlow 0500 mA Flow 0000 mA

Item name Explanation Setting range Default value Item name Explanation Setting range Default value
tEng Target engine speed 500 to max speed Low idling tEng Target engine speed 500 to max speed Low idling
tPower Target milli-amp for horsepower control proportional valve 50 to 740 50 tPower Target milli-amp for horsepower control proportional valve 50 to 740 50
tFlow Target milli-amp for flow control proportional valve 50 to 740 50 tFlow Target milli-amp for flow control proportional valve 50 to 740 50
P1+P2 P1+P2 pressure - - P1+P2 P1+P2 pressure - -
Eng Actual engine speed - - Eng Actual engine speed - -
Power Actual milli-amp for horsepower control proportional valve - - Power Actual milli-amp for horsepower control proportional valve - -
Flow Actual milli-amp for flow control proportional valve - - Flow Actual milli-amp for flow control proportional valve - -

3) Hydraulic pressure drive fan override 3) Hydraulic pressure drive fan override

Item name Explanation Setting range Default value Item name Explanation Setting range Default value
Eng Actual engine speed - - Eng Actual engine speed - -
Coolnt Coolant temperature - - Coolnt Coolant temperature - -
tFan Target milli-amp for hydraulic fan proportional valve fan current - - tFan Target milli-amp for hydraulic fan proportional valve fan current - -
HydOil Oil temperature - - HydOil Oil temperature - -
FuelT Fuel temperature - - FuelT Fuel temperature - -
BstT Boost temperature - - BstT Boost temperature - -
Fan Actual milli-amp for hydraulic fan proportional valve fan current - - Fan Actual milli-amp for hydraulic fan proportional valve fan current - -

4) Crane initial adjustment 4) Crane initial adjustment

Item name Explanation Setting range Default value Item name Explanation Setting range Default value
Cyl (B) Boom cylinder bottom pressure - - Cyl (B) Boom cylinder bottom pressure - -
Cyl (R) Boom cylinder rod pressure - - Cyl (R) Boom cylinder rod pressure - -
-3- * - - -3- * - -
STEP Adjustment step number 0 - Maximum value 0 - Maximum STEP Adjustment step number 0 - Maximum value 0 - Maximum
value value
Bm A Angle sensor voltage value - - Bm A Angle sensor voltage value - -
Am A Angle sensor voltage value - - Am A Angle sensor voltage value - -
Of A Angle sensor voltage value - - Of A Angle sensor voltage value - -

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-109 4001-109

5) Interference prevention initial adjustment 5) Interference prevention initial adjustment

Item name Explanation Setting range Default value Item name Explanation Setting range Default value
Cyl (B) Boom cylinder bottom pressure - - Cyl (B) Boom cylinder bottom pressure - -
Cyl (R) Boom cylinder rod pressure - - Cyl (R) Boom cylinder rod pressure - -
-3- * - - -3- * - -
STEP Adjustment step number 0 - Maximum value 5 STEP Adjustment step number 0 - Maximum value 5
Bm A Angle sensor voltage value - - Bm A Angle sensor voltage value - -
Am A Angle sensor voltage value - - Am A Angle sensor voltage value - -
Of A Angle sensor voltage value - - Of A Angle sensor voltage value - -

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-110 4001-110

6. Check the Monitor Switch (Self-diagnosis function) 6. Check the Monitor Switch (Self-diagnosis function)

A) Screen A) Screen
After the key is switched ON, the "CASE" logo screen is displayed on the monitor. After the key is switched ON, the "CASE" logo screen is displayed on the monitor.
At this time, the display can be switched to the monitor switch check screen by pressing the one-touch idle At this time, the display can be switched to the monitor switch check screen by pressing the one-touch idle
switch five times. switch five times.

The switch contents are as follows: The switch contents are as follows:
WIPER SW Wiper Switch WIPER SW Wiper Switch
SW1 Front window limit switch WASHER SW Washer Switch SW1 Front window limit switch WASHER SW Washer Switch
SW2 Breaker mode switch W. LAMP SW Working light switch SW2 Breaker mode switch W. LAMP SW Working light switch
SW3 Crusher mode switch T. MODE SW Travel high-speed select switch SW3 Crusher mode switch T. MODE SW Travel high-speed select switch
SW4 2 pumps flow switch A. IDLE SW Auto idle switch SW4 2 pumps flow switch A. IDLE SW Auto idle switch
SW5 Not Used HORN VOL. SW Horn volume select switch SW5 Not Used HORN VOL. SW Horn volume select switch

B) Configuration B) Configuration

6 Wiper switch 6 Wiper switch


1 Washer switch 1 Washer switch
Working light switch Working light switch
Travel high-speed Travel high-speed
select switch select switch
EXT-SW1 Auto idle switch EXT-SW1 Auto idle switch
2 2
Horn volume select Horn volume select
switch switch

EXT-SW2 EXT-SW2
3 3

EXT-SW3 EXT-SW3
4 4

EXT-SW4 EXT-SW4
5 No communications 5 No communications
with computer A with computer A
(Monitor alone) (Monitor alone)

Not used EXT-SW5 Not used EXT-SW5


x x

1 Switch panel 4 Breaker mode switch 1 Switch panel 4 Breaker mode switch
2 2 pumps flow switch 5 Crusher mode switch 2 2 pumps flow switch 5 Crusher mode switch
3 Front window limit switch 6 Monitor 3 Front window limit switch 6 Monitor
Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07
4001-111 4001-111
C) Differences from CHK screen [CHK | H/W-M | 1] C) Differences from CHK screen [CHK | H/W-M | 1]
Monitor main unit input / output can also be checked on the CHK screen. Monitor main unit input / output can also be checked on the CHK screen.
However, for the CHK screen, after the switch input is sent to computer A with communication, the switch input However, for the CHK screen, after the switch input is sent to computer A with communication, the switch input
is processed by computer A and the results are sent to the monitor as screen data and displayed. is processed by computer A and the results are sent to the monitor as screen data and displayed.
On the monitor switch check screen, the switch input recognized by the monitor itself is displayed directly on On the monitor switch check screen, the switch input recognized by the monitor itself is displayed directly on
the screen (without involving communications or Computer A), so it is possible to diagnose purely the switches the screen (without involving communications or Computer A), so it is possible to diagnose purely the switches
themselves. themselves.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-112 4001-112

7. Option Flow Setting 7. Option Flow Setting

A) Screen A) Screen
When three seconds have passed, the logo screen shifts to the user screen. When three seconds have passed, the logo screen shifts to the user screen.
With the user screen being displayed, if either the "breaker" or "crusher" rocker switch on the right panel is held With the user screen being displayed, if either the "breaker" or "crusher" rocker switch on the right panel is held
down for 3 seconds, the "option flow setting screen" is displayed on the monitor. down for 3 seconds, the "option flow setting screen" is displayed on the monitor.

Option line icon: Option line icon:


Displays the option line for which the Displays the option line for which the
flow is set (select for the breaker 1/2/ flow is set (select for the breaker 1/2/
3/4/5 and crusher 1/2/3/4/5). 3/4/5 and crusher 1/2/3/4/5).

D i s p l ay s t h e m a x i m u m f l o w fo r D i s p l ay s t h e m a x i m u m f l o w fo r
1 pump. 1 pump.
D i s p l ay s t h e m a x i m u m f l o w fo r D i s p l ay s t h e m a x i m u m f l o w fo r
2 pumps. 2 pumps.
Pump discharge pressure (P1 pump Pump discharge pressure (P1 pump
main pressure). main pressure).

B) Flow setting B) Flow setting


1. Press the breaker or crusher mode switch to select the mode to set the flow for. 1. Press the breaker or crusher mode switch to select the mode to set the flow for.

Rocker switch Rocker switch


1 1

3 3

2 4 2 4

1 Flow increase 3 Crusher mode (1 to 5) switchover 1 Flow increase 3 Crusher mode (1 to 5) switchover
2 Flow decrease 4 Breaker mode (1 to 5) switchover 2 Flow decrease 4 Breaker mode (1 to 5) switchover

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-113 4001-113

2. The flow setting for the selected mode is selected by pressing the wiper switch or auto idle select switch. 2. The flow setting for the selected mode is selected by pressing the wiper switch or auto idle select switch.
The flow setting can be set to 10 levels from Level 1 to Level 10. The flow setting can be set to 10 levels from Level 1 to Level 10.

CAUTION: The set flow is the flow value when SP mode is selected. CAUTION: The set flow is the flow value when SP mode is selected.
Be careful. If run with the engine speed reduced, the actual flow is not the flow displayed. Be careful. If run with the engine speed reduced, the actual flow is not the flow displayed.

Unit Unit
1 pump flow (flow Level 1) L / min 129 1 pump flow (flow Level 1) L / min 129
1 pump flow (flow Level 2) L / min 119 1 pump flow (flow Level 2) L / min 119
1 pump flow (flow Level 3) L / min 106 1 pump flow (flow Level 3) L / min 106
1 pump flow (flow Level 4) L / min 100 1 pump flow (flow Level 4) L / min 100
1 pump flow (flow Level 5) L / min 87 1 pump flow (flow Level 5) L / min 87
1 pump flow (flow Level 6) L / min 75 1 pump flow (flow Level 6) L / min 75
1 pump flow (flow Level 7) L / min 64 1 pump flow (flow Level 7) L / min 64
1 pump flow (flow Level 8) L / min 53 1 pump flow (flow Level 8) L / min 53
1 pump flow (flow Level 9) L / min 39 1 pump flow (flow Level 9) L / min 39
1 pump flow (flow Level 10) L / min 35 1 pump flow (flow Level 10) L / min 35
2 pumps flow (flow Level 1) L / min 258 2 pumps flow (flow Level 1) L / min 258
2 pumps flow (flow Level 2) L / min 248 2 pumps flow (flow Level 2) L / min 248
2 pumps flow (flow Level 3) L / min 235 2 pumps flow (flow Level 3) L / min 235
2 pumps flow (flow Level 4) L / min 229 2 pumps flow (flow Level 4) L / min 229
2 pumps flow (flow Level 5) L / min 216 2 pumps flow (flow Level 5) L / min 216
2 pumps flow (flow Level 6) L / min 204 2 pumps flow (flow Level 6) L / min 204
2 pumps flow (flow Level 7) L / min 193 2 pumps flow (flow Level 7) L / min 193
2 pumps flow (flow Level 8) L / min 182 2 pumps flow (flow Level 8) L / min 182
2 pumps flow (flow Level 9) L / min 168 2 pumps flow (flow Level 9) L / min 168
2 pumps flow (flow Level 10) L / min 164 2 pumps flow (flow Level 10) L / min 164
3. There is no need to do anything to finalize the setting. End by leaving this screen or switching OFF the 3. There is no need to do anything to finalize the setting. End by leaving this screen or switching OFF the
key. key.
The factory settings for each mode are as follows. The factory settings for each mode are as follows.
There are no 4 or 5 settings for the breaker or crusher. Just a hyphen is displayed for these settings. There are no 4 or 5 settings for the breaker or crusher. Just a hyphen is displayed for these settings.

Mode Flow display Mode Flow display


Breaker circuit 1 / Crusher 1 Level 3 flow Breaker circuit 1 / Crusher 1 Level 3 flow
Breaker circuit 2 / Crusher 2 Level 5 flow Breaker circuit 2 / Crusher 2 Level 5 flow
Breaker circuit 3 / Crusher 3 Level 7 flow Breaker circuit 3 / Crusher 3 Level 7 flow
Breaker circuit 4 / Crusher 4 ----(Not used) Breaker circuit 4 / Crusher 4 ----(Not used)
Breaker circuit 5 / Crusher 5 Breaker circuit 5 / Crusher 5

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-114 4001-114

8. Anti-theft Setting 8. Anti-theft Setting

A) Anti-theft setting and password registration A) Anti-theft setting and password registration
1) Enabling the anti-theft function 1) Enabling the anti-theft function
With the key OFF, connect the anti-theft knob terminal. With the key OFF, connect the anti-theft knob terminal.
When the male and female knob terminals are connected on the cab main harness in the rear cover, the anti- When the male and female knob terminals are connected on the cab main harness in the rear cover, the anti-
theft function is enabled.The factory setting is for these knob terminals to be disconnected. theft function is enabled.The factory setting is for these knob terminals to be disconnected.
Anti-theft protection setting knob Anti-theft protection setting knob
Connect VG (purple / green) and BG (black Connect VG (purple / green) and BG (black
/ green) / green)

2) Setting the password 2) Setting the password


When the knob terminals are connected, then the key switched ON, the following screen is displayed. When the knob terminals are connected, then the key switched ON, the following screen is displayed.
Enter any 4-digit number made up of the numbers 1 to 9. Enter any 4-digit number made up of the numbers 1 to 9.
(If all four digits are not input, "ERROR" is displayed). (If all four digits are not input, "ERROR" is displayed).
Input by using the monitor switches as follows. Input by using the monitor switches as follows.
When the Enter button is pressed, the password is stored into memory and display returns to the normal When the Enter button is pressed, the password is stored into memory and display returns to the normal
screen. screen.

3 3

1 1

2 2

1 Enter 3 Numeric value increase / decrease 1 Enter 3 Numeric value increase / decrease
2 Cursor movement 2 Cursor movement

3) Changing the password 3) Changing the password


If the password has been forgotten or it is desired to change the password, if the knob terminal in A)1) is If the password has been forgotten or it is desired to change the password, if the knob terminal in A)1) is
disconnected and the key switched ON, the password is cleared. To re-input the password, repeat the disconnected and the key switched ON, the password is cleared. To re-input the password, repeat the
procedure in b). procedure in b).

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-115 4001-115

B) Anti-theft function operation B) Anti-theft function operation


1) Enabling the anti-theft function 1) Enabling the anti-theft function
1. If the key is switched twice in a row ON => OFF => ON => OFF with the engine stopped, the anti-theft 1. If the key is switched twice in a row ON => OFF => ON => OFF with the engine stopped, the anti-theft
function is switched ON. function is switched ON.
(All the key switching operations must be done within 2 seconds) (All the key switching operations must be done within 2 seconds)
2. When the anti-theft comes ON, the monitor buzzes and the "key" icon is displayed. 2. When the anti-theft comes ON, the monitor buzzes and the "key" icon is displayed.
(Once the anti-theft is switched ON, this icon is displayed while the power is OFF) (Once the anti-theft is switched ON, this icon is displayed while the power is OFF)

3. The next time the key is switched ON, the anti-theft operates and the password input screen is displayed. 3. The next time the key is switched ON, the anti-theft operates and the password input screen is displayed.
Input the password made up of 4 digits 0 to 9. Input the password made up of 4 digits 0 to 9.
Input by using the monitor switches below. Input by using the monitor switches below.
If an incorrect number is input, "ERROR" is displayed and the buzzer buzzes. If an incorrect number is input, "ERROR" is displayed and the buzzer buzzes.
The key must be switched OFF, then ON again before the password can be re-input. The key must be switched OFF, then ON again before the password can be re-input.

3 3

1 1

2 2

1 Enter 3 Numeric value increase / decrease 1 Enter 3 Numeric value increase / decrease
2 Cursor movement 2 Cursor movement

2) Disabling the anti-theft function 2) Disabling the anti-theft function


1. If the engine is stopped by switching OFF the key, the anti-theft function does not operate. 1. If the engine is stopped by switching OFF the key, the anti-theft function does not operate.
2. To disable the anti-theft function, disconnect the anti-theft knob terminals VG (purple/green) and BG 2. To disable the anti-theft function, disconnect the anti-theft knob terminals VG (purple/green) and BG
(black/green). The registered password is canceled. (black/green). The registered password is canceled.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-116 4001-116

9. Model Setting 9. Model Setting


If the model selection has not been completed, immediately after the key is switched ON, the "Model select screen" If the model selection has not been completed, immediately after the key is switched ON, the "Model select screen"
is displayed is displayed

1 Cursor 3 Computer B; Part number 1 Cursor 3 Computer B; Part number


2 Computer A; Part number 4 Error display section 2 Computer A; Part number 4 Error display section
1. For the "CONT.A" item, the part number for computer A is automatically displayed. 1. For the "CONT.A" item, the part number for computer A is automatically displayed.
2. In the same way, if computer B is connected (for the liftcrane specifications or interference prevention 2. In the same way, if computer B is connected (for the liftcrane specifications or interference prevention
specifications), the part number for computer B is automatically displayed for the "CONT. B" item. specifications), the part number for computer B is automatically displayed for the "CONT. B" item.
3. Items that must be input are displayed with '?'. 3. Items that must be input are displayed with '?'.
MACHINE : Model CX130B,CX160B,CX180B,CX210B,CX230B, CX240B,CX290B ... MACHINE : Model CX130B,CX160B,CX180B,CX210B,CX230B, CX240B,CX290B ...
TERRITORY : Destination 2 = CASE NA, 3= CASE EU TERRITORY : Destination 2 = CASE NA, 3= CASE EU
LANGUAGE : Language (0: Japanese, 1: English, 2: Thai, 3: Chaina, 4: German, 5: French, LANGUAGE : Language (0: Japanese, 1: English, 2: Thai, 3: Chaina, 4: German, 5: French,
6 : I t a l i a n , 7 : S p a n i s h , 8 : Po r t u g u e s e, 9 : D u t c h , 1 0 : D a n i s h , 6 : I t a l i a n , 7 : S p a n i s h , 8 : Po r t u g u e s e, 9 : D u t c h , 1 0 : D a n i s h ,
11: Norwegian, 12: Swedish, 13: Finnish, 14: Turkish, 15: Arabic, 11: Norwegian, 12: Swedish, 13: Finnish, 14: Turkish, 15: Arabic,
16: Malay, 17: Indonesian, 18: Icon) 16: Malay, 17: Indonesian, 18: Icon)
SPEC : Main unit specifications (input 0) SPEC : Main unit specifications (input 0)
ATT.No. : Attachment specification (input 0) ATT.No. : Attachment specification (input 0)

4. Input operating method 4. Input operating method


Input by using the monitor switches as follows. Input by using the monitor switches as follows.
When the model select screen is displayed on the monitor, the normal monitor switch functions do not When the model select screen is displayed on the monitor, the normal monitor switch functions do not
work. work.
1) Enter button 1) Enter button

3 2) Numeric value change 3 2) Numeric value change

3) Cursor movement 3) Cursor movement


1 1

2 2
When the throttle volume position or all the input is complete, press " " (Enter button). When the throttle volume position or all the input is complete, press " " (Enter button).
(The throttle volume must always be at the "H" mode position). (The throttle volume must always be at the "H" mode position).
If the input is inappropriate (*), "CONT. A. ERR" is displayed. If the input is inappropriate (*), "CONT. A. ERR" is displayed.
* When there is still an item left with "?" displayed or the combination of model, destination, specification, * When there is still an item left with "?" displayed or the combination of model, destination, specification,
and the like is inappropriate. and the like is inappropriate.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-117 4001-117
5. On the model setting screen, the ECM part number is automatically checked. 5. On the model setting screen, the ECM part number is automatically checked.
If the input model and the ECM part number do not correspond, “ECM ERR” is displayed. If the input model and the ECM part number do not correspond, “ECM ERR” is displayed.
6. Even after the model selection is complete, it is possible to change just the LANGUAGE setting without 6. Even after the model selection is complete, it is possible to change just the LANGUAGE setting without
one of the half resets or all resets listed below. one of the half resets or all resets listed below.
7. Half reset 7. Half reset
• On the model select screen, if the washer switch and the light switch are held down for 3 • On the model select screen, if the washer switch and the light switch are held down for 3
seconds, the data in the table below are erased. seconds, the data in the table below are erased.
8. All reset 8. All reset
• On the model select screen, if the washer switch and the light switch are held for 10 • On the model select screen, if the washer switch and the light switch are held for 10
seconds, data in the table below is erased. seconds, data in the table below is erased.
Difference between all reset and half reset Difference between all reset and half reset

Reset ....................................................................... O Reset ....................................................................... O


Not reset .................................................................. O Not reset .................................................................. O
Reset when model information has changed. ............ Δ Reset when model information has changed. ............ Δ
Half reset All reset Half reset All reset
Computer A memory information Model information (*1) O O Computer A memory information Model information (*1) O O
Control data (*2) O O Control data (*2) O O
Usage log (*3) O O Usage log (*3) O O
Trouble log (*4) x O Trouble log (*4) x O
Engine information (*5) x O Engine information (*5) x O
Computer S memory information Transmission information (*6) x O Computer S memory information Transmission information (*6) x O

*1 Contents displayed on model selection screen *1 Contents displayed on model selection screen
*2 Contents displayed on CFG screen *2 Contents displayed on CFG screen
*3 Contents displayed on HR screen *3 Contents displayed on HR screen
*4 Contents displayed on DIAG screen *4 Contents displayed on DIAG screen
*5 Contents displayed on engine service screen *5 Contents displayed on engine service screen
*6 When transmission information is reset, transmission with the G@NAV server is restarted from the initial send. *6 When transmission information is reset, transmission with the G@NAV server is restarted from the initial send.
In this case, transmission with the G@NAV server cannot be done until a send permission signal is sent In this case, transmission with the G@NAV server cannot be done until a send permission signal is sent
from the control center. from the control center.

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4001-118 4001-118

10. Engine Screen Information 10. Engine Screen Information

A) Purpose A) Purpose
It has been made possible to copy the engine information (Q adjustment, QR code, engine serial It has been made possible to copy the engine information (Q adjustment, QR code, engine serial
number) stored in the ECM to the new ECM when the ECM and injector are replaced. number) stored in the ECM to the new ECM when the ECM and injector are replaced.

B) How to go to this screen B) How to go to this screen


See the service support screen operation. See the service support screen operation.

C) Engine start restriction C) Engine start restriction


When this screen is displayed, the engine cannot be started. When this screen is displayed, the engine cannot be started.

D) Screen D) Screen
The engine information held in computer A can be checked as follows. The engine information held in computer A can be checked as follows.
1. Pages 1 to 4: Injector cylinder 1 to 4 QR code (Pages 5 and 6 are not used and cannot be input). 1. Pages 1 to 4: Injector cylinder 1 to 4 QR code (Pages 5 and 6 are not used and cannot be input).
1) Page 1) Page

2) QR code 24 digits 2) QR code 24 digits

3) Error code 3) Error code

4) Indicates the display mode. 4) Indicates the display mode.


Currently displays the information in Currently displays the information in
computer A computer A

2. Page 7: Q resistance data 2. Page 7: Q resistance data


1) Q resistance data 3 digits 1) Q resistance data 3 digits

3. Page 8: Engine serial (number) 3. Page 8: Engine serial (number)


1) Engine serial number 6 digits 1) Engine serial number 6 digits

4. ECM Part Number 4. ECM Part Number


1) ECM part number 1) ECM part number

E) Operating method E) Operating method


See the Engine Maintenance Standards See the Engine Maintenance Standards

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4001-119 4001-119
F) Monitor operation method F) Monitor operation method
1) View Mode. 1) View Mode.

Display mode (switching between information Display mode (switching between information
in controller A / information in ECM) in controller A / information in ECM)
page +/- page +/-
Each time this switch is pressed, the second Each time this switch is pressed, the second
line of each page is switched as follows. line of each page is switched as follows.

Hold down for one second to shift to Edit Mode Hold down for one second to shift to Edit Mode
AA AA (Mode displaying information (only valid while QR code displayed and when in AA AA (Mode displaying information (only valid while QR code displayed and when in
in computer A) "AA AA" mode) in computer A) "AA AA" mode)
Be careful. Shifting to edit mode will not be done Be careful. Shifting to edit mode will not be done
EE EE (Mode displaying information when in "EE EE" mode EE EE (Mode displaying information when in "EE EE" mode
in ECM) in ECM)
Hold down for three seconds to start copying the engine Hold down for three seconds to start copying the engine
information. information.
For details see "Engine Information Copying Method" For details see "Engine Information Copying Method"

2) Edit Mode 2) Edit Mode


Can only be shifted to during QR code display. Can only be shifted to during QR code display.

Cancel editing and exit edit mode Value increased Cancel editing and exit edit mode Value increased

Cursor movement Cursor movement


Start the QR code writing and exit edit mode. Start the QR code writing and exit edit mode.
For details see "Rewr iting Injector QR Value decreased For details see "Rewr iting Injector QR Value decreased
Codes" Codes"

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4001-120 4001-120

G) Engine Information (Q resistance, QR code, engine serial number) Copying Method G) Engine Information (Q resistance, QR code, engine serial number) Copying Method
If the ECM is replaced with a new one for any reason, the engine information is copied with the procedure If the ECM is replaced with a new one for any reason, the engine information is copied with the procedure
below below
1. Connect the service ECM and check the following. 1. Connect the service ECM and check the following.
• The old ECM information must still be in computer A. • The old ECM information must still be in computer A.
• The ECM must match the model (Check on the ECM parts nimber screen). • The ECM must match the model (Check on the ECM parts nimber screen).
• No display for faulty computer A EEPROM or faulty EEPROM on ECM. • No display for faulty computer A EEPROM or faulty EEPROM on ECM.
2. Go to the engine information screen, then hold down for 3 seconds. The buzzer buzzes and the copy 2. Go to the engine information screen, then hold down for 3 seconds. The buzzer buzzes and the copy
starts. starts.
• The display may be any page (1 to 8) and either display mode (computer A or ECM). • The display may be any page (1 to 8) and either display mode (computer A or ECM).

When held for three seconds, the When held for three seconds, the
buzzer buzzes. buzzer buzzes.

During copying, the display is as below. During writing, the error code 99 is displayed. During copying, the display is as below. During writing, the error code 99 is displayed.
Wait about 10 seconds. Wait about 10 seconds.
When the copy ends normally, the error code 00 is displayed. When the copy ends normally, the error code 00 is displayed.
When the copy ends abnormally, error code displayed. When the copy ends abnormally, error code displayed.
• Example: Starting copying from the Q resistance screen. • Example: Starting copying from the Q resistance screen.
Error Code: Error Code:
00: Normal. 00: Normal.
01: Message interruption. 01: Message interruption.
02: Message internal trouble. 02: Message internal trouble.
03: Outside instruction value constant. 03: Outside instruction value constant.
04: Engine running. 04: Engine running.
98: Faulty EEPROM 98: Faulty EEPROM
99: Writing 99: Writing
During rewriting, the mode display During rewriting, the mode display
section is "0". section is "0".

3. When the copy ends normally, check that the information has been rewritten by switching the key switch 3. When the copy ends normally, check that the information has been rewritten by switching the key switch
OFF => ON once. OFF => ON once.

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4001-121 4001-121

H) Rewriting Injector QR Codes H) Rewriting Injector QR Codes


When an injector is replaced, input and write the QR codes with the following procedure. When an injector is replaced, input and write the QR codes with the following procedure.
1. Arrange for the replacement injector. 1. Arrange for the replacement injector.
Input the part below from the character array written on the injector Input the part below from the character array written on the injector

QR Code QR Code
QR Code QR Code

Injector ASM Injector ASM

Input section 24 digits Input section 24 digits

Input the QR codes one at a time. Input the QR codes one at a time.
Engine information screen Pages 1 to 4 (4 cylinders engine) or Pages 1 to 6 (6 cylinders engine) Engine information screen Pages 1 to 4 (4 cylinders engine) or Pages 1 to 6 (6 cylinders engine)
correspond to the injectors with those numbers (See the figure below.) correspond to the injectors with those numbers (See the figure below.)

Engine rear Engine rear


Engine front
1 2 3 4 Engine front
1 2 3 4

Injector No. Injector No.

Engine rear Engine rear


Engine front
1 2 3 4 5 6 Engine front
1 2 3 4 5 6

Injector No. Injector No.


2. Hold down the idle switch for 1 second to shift the Edit mode. 2. Hold down the idle switch for 1 second to shift the Edit mode.

Hold down for 1 second Hold down for 1 second

3. Cursor is displayed. 3. Cursor is displayed.

ENG. INF 1 ENG. INF 1


5A 52 70 1E 35 DD 21 57 00 1F 5A 5A 52 70 1E 35 DD 21 57 00 1F 5A
BD AA AA 00 Cursor displayed BD AA AA 00 Cursor displayed

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4001-122 4001-122
4. Move the cursor with the washer and light switchs. Use the wiper and the auto idle switchs to raise and 4. Move the cursor with the washer and light switchs. Use the wiper and the auto idle switchs to raise and
lower the value and input the QR codes written on the injector. lower the value and input the QR codes written on the injector.

Value increased / decreased Value increased / decreased

Cursor Cursor
movement movement

Error Code: Error Code:


00: Normal. 00: Normal.
ENG. INF 1 01: Message interruption. ENG. INF 1 01: Message interruption.
5A 52 70 1E 35 DD 21 57 00 1F 5A 02: Message internal trouble. 5A 52 70 1E 35 DD 21 57 00 1F 5A 02: Message internal trouble.
BD AA AA 00 03: Outside instruction value constant. BD AA AA 00 03: Outside instruction value constant.
04: Engine running. 04: Engine running.
98: Faulty EEPROM 98: Faulty EEPROM
99: Writing 99: Writing
Cursor only moves as Cursor only moves as
far as here far as here

5. When the QR code input is complete, press . 5. When the QR code input is complete, press .
The buzzer buzzes once and the writing starts. The buzzer buzzes once and the writing starts.
The error code 99 (writing) is displayed. When the copy ends normally, the error code 00 is displayed. The error code 99 (writing) is displayed. When the copy ends normally, the error code 00 is displayed.
When the writing ends abnormally, the buzzer buzzes twice and the error code is displayed. (To cancel When the writing ends abnormally, the buzzer buzzes twice and the error code is displayed. (To cancel
input, press the horn switch) input, press the horn switch)
6. Switch OFF the key switch, then ON again and check that the QR codes have been written. 6. Switch OFF the key switch, then ON again and check that the QR codes have been written.

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4001-123 4001-123

I) When Replacing Computer A at the Same Time I) When Replacing Computer A at the Same Time
If the ECM and computer A have trouble at the same time and the engine information inside the ECM cannot If the ECM and computer A have trouble at the same time and the engine information inside the ECM cannot
be used, restore the engine information with the procedure below. be used, restore the engine information with the procedure below.
1. Rather than a service ECM, arrange for an ECM with the engine information already written into it and 1. Rather than a service ECM, arrange for an ECM with the engine information already written into it and
use that as the replacement. use that as the replacement.
• An ECM with the engine information already written into it means one into which the Q resistance • An ECM with the engine information already written into it means one into which the Q resistance
data has been written with EMPS. data has been written with EMPS.
2. Input the injector QR codes one at a time (with the procedure in the preceding item). 2. Input the injector QR codes one at a time (with the procedure in the preceding item).

J) Engine Information Obtained Timing J) Engine Information Obtained Timing


The engine information is acquired only the first time the key is switched ON after assembly. The engine information is acquired only the first time the key is switched ON after assembly.

K) Redoing Engine Information Obtained K) Redoing Engine Information Obtained


To re-aquire the engine information, on the engine information screen, hold down the washer switch and the To re-aquire the engine information, on the engine information screen, hold down the washer switch and the
light switch for 10 seconds. light switch for 10 seconds.

L) Trouble Display L) Trouble Display


If the engine information cannot be displayed correctly due to an ECM time-out, CAN communications trouble, If the engine information cannot be displayed correctly due to an ECM time-out, CAN communications trouble,
or faulty EEPROM, the display is all Fs. or faulty EEPROM, the display is all Fs.
• Display for faulty ECM EEPROM, CAN communications trouble, or ECM time-out • Display for faulty ECM EEPROM, CAN communications trouble, or ECM time-out

ENG. INF 1 ENG. INF 1


FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF
FF EE EE 00 FF EE EE 00

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Screen Display Details Screen Display Details
1. Message Display List 1. Message Display List
Display Message Display ON timing Display OFF timing Display Message Display ON timing Display OFF timing
type type
When the "engine oil pressure abnormally low" trouble When the "engine oil pressure abnormally low" trouble
LOW OIL PRESS Warning occurs LOW OIL PRESS Warning occurs

When the "ECM mismatch" trouble occurs. When the "ECM mismatch" trouble occurs.
CHECK ENGINE Warning Also, when a diagnostic trouble code is sent from the CHECK ENGINE Warning Also, when a diagnostic trouble code is sent from the
ECM ECM
When any of the troubles below occur When any of the troubles below occur
Pressure Sensors; (P1), (P2), (N1), (N2), (Overload), Pressure Sensors; (P1), (P2), (N1), (N2), (Overload),
(Bottom), (Rod), (Upper), (Swing), (Travel), (Bottom), (Rod), (Upper), (Swing), (Travel),
Sensor; Fuel level, None Does not go off Sensor; Fuel level, None Does not go off
Temperature Sensors; (Oil), while the key is ON. Temperature Sensors; (Oil), while the key is ON.
Pressure switch; (Return filter clog), Pressure switch; (Return filter clog),
Solenoid; (Swing brake), (Travel high-speed), (Option Solenoid; (Swing brake), (Travel high-speed), (Option
ELEC. PROBLEM ELEC. PROBLEM
Warning return circuit),(Free swing), Warning return circuit),(Free swing),
(*1) (*1)
Air conditioner signal output, Air conditioner signal output,
Relay; Feed pump automatic stop, Relay; Feed pump automatic stop,
Rotating light and solenoid bucket lock Rotating light and solenoid bucket lock
Proportional valve; (Horsepower pump), (Pump flow), Proportional valve; (Horsepower pump), (Pump flow),
Communication (monitor), (ECM), (computer B), Communication (monitor), (ECM), (computer B),
(computer S), (computer S),
CAN bus CAN bus
When any of the troubles below occur When all the troubles When any of the troubles below occur When all the troubles
"Abnormally high coolant temperature 1", "Abnormally below are recovered "Abnormally high coolant temperature 1", "Abnormally below are recovered
high oil temperature" from "Abnormally high high oil temperature" from "Abnormally high
OVERHEAT Warning OVERHEAT Warning
coolant temperature 1" coolant temperature 1"
"Abnormally high oil "Abnormally high oil
temperature" temperature"
When the "Coolant level low" trouble occurs When the "Coolant level low" trouble occurs
LOW COOLANT Warning LOW COOLANT Warning

When the "Abnormally low alternator voltage" trouble When the "Abnormally low alternator voltage" trouble
ALTERNATOR Warning occurs ALTERNATOR Warning occurs
None Does not go off None Does not go off
CHECK HYD.OIL When the "Return filter clogged" trouble occurs while the key is ON. CHECK HYD.OIL When the "Return filter clogged" trouble occurs while the key is ON.
Warning Warning
FILTER FILTER
When the "Air cleaner clogged" trouble occurs When the "Air cleaner clogged" trouble occurs
AIR FILTER Warning AIR FILTER Warning

When the "Abnormally high boost temperature 1" trouble When the "Abnormally When the "Abnormally high boost temperature 1" trouble When the "Abnormally
occurs high boost occurs high boost
BOOST TEMP.HIGH Warning BOOST TEMP.HIGH Warning
temperature 1" trouble temperature 1" trouble
is recovered from is recovered from
When the "Fuel level drop" trouble occurs When the "Fuel level When the "Fuel level drop" trouble occurs When the "Fuel level
LOW FUEL Warning low" trouble is LOW FUEL Warning low" trouble is
recovered from recovered from
When the breaker mode is ON and 2nd speed flow is ON When the breaker mode is ON and 2nd speed flow is ON
SWITCH TO 1-PUMP Alert SWITCH TO 1-PUMP Alert

When the engine emergency stop switch is ON When the conditions on When the engine emergency stop switch is ON When the conditions on
ENGINE STOP Alert the left are no longer ENGINE STOP Alert the left are no longer
met met
When the boom cylinder bottom pressure exceeds the set When the boom cylinder bottom pressure exceeds the set
OVER LOAD Alert pressure OVER LOAD Alert pressure

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4001-125 4001-125

Display Message Display ON timing Display OFF timing Display Message Display ON timing Display OFF timing
type type
During one-touch idling or auto idling During one-touch idling or auto idling
ENGIN IDLING Icon ENGIN IDLING Icon

During auto power boost When the conditions on During auto power boost When the conditions on
POWER UP Icon POWER UP Icon
the left are no longer the left are no longer
When power ON to glow plug met When power ON to glow plug met
ENG. PRE HEAT Icon ENG. PRE HEAT Icon

During auto warm up During auto warm up


AUTO WARM UP Icon AUTO WARM UP Icon

When the crane interference prevention initial adjustment When the conditions on When the crane interference prevention initial adjustment When the conditions on
INITIAL SETTINGS INITIAL SETTINGS
Status has not been completed the left are no longer Status has not been completed the left are no longer
INCOMPLETE INCOMPLETE
met met
When the key is ON and the hour meter has reached the After 1 minute after the When the key is ON and the hour meter has reached the After 1 minute after the
SERVICE DUE Status regulation time SERVICE DUE Status regulation time
key was switched ON key was switched ON
(*1) Even if one of the following troubles occurs, "ELEC. PROBLEM" is not issued. (*1) Even if one of the following troubles occurs, "ELEC. PROBLEM" is not issued.
"BZ travel alarm", "Monitor thermistor", "Air conditioner coolant signal output" "BZ travel alarm", "Monitor thermistor", "Air conditioner coolant signal output"
Message type: Message type:
1. Status (Message only) 1. Status (Message only)
2. Alert (The intermittent alarm continues to sound at one-second intervals) 2. Alert (The intermittent alarm continues to sound at one-second intervals)
3. Warning (The continuous alarm sounds for just 5 seconds) 3. Warning (The continuous alarm sounds for just 5 seconds)
4. Icon (Only an icon is displayed). 4. Icon (Only an icon is displayed).

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4001-126 4001-126
Trouble Display Trouble Display
1. Diagnostic Trouble Code Display 1. Diagnostic Trouble Code Display
1) Purpose and summary 1) Purpose and summary
When a trouble occurs, the diagnostic trouble code (DTC) is displayed on the user screen. When a trouble occurs, the diagnostic trouble code (DTC) is displayed on the user screen.
This enables the operator to verbally communicate the trouble to the service engineer. This enables the operator to verbally communicate the trouble to the service engineer.

2) Screen 2) Screen
Displayed with the ! mark next to the work mode followed by a four-digit number. Displayed with the ! mark next to the work mode followed by a four-digit number.
If there is no trouble, nothing at all is displayed. If there is no trouble, nothing at all is displayed.

ELEC. PROBLEM ELEC. PROBLEM

3) Trouble display 3) Trouble display


The "ELEC. PROBLEM" or "CHECK ENGINE" message is displayed. The "ELEC. PROBLEM" or "CHECK ENGINE" message is displayed.
When trouble occurs, the corresponding diagnostic trouble code is displayed. If the message makes clear When trouble occurs, the corresponding diagnostic trouble code is displayed. If the message makes clear
the trouble location, the location is not displayed elsewhere. the trouble location, the location is not displayed elsewhere.
For details, see the "Main Unit Diagnostic Trouble Code List". All the diagnostic trouble codes sent from the For details, see the "Main Unit Diagnostic Trouble Code List". All the diagnostic trouble codes sent from the
ECM are subject to display. ECM are subject to display.

4) Displayed trouble status 4) Displayed trouble status


Only current and ongoing troubles are displayed.Troubles that have been recovered from are not displayed. Only current and ongoing troubles are displayed.Troubles that have been recovered from are not displayed.

5) Multiple trouble display 5) Multiple trouble display


When multiple troubles occur, they are displayed in turn at intervals of five seconds. When multiple troubles occur, they are displayed in turn at intervals of five seconds.

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4001-127 4001-127

2. Main Unit Diagnostic Trouble Code List 2. Main Unit Diagnostic Trouble Code List
1) Electrical troubles (input) [7000-7199] 1) Electrical troubles (input) [7000-7199]

Diagnostic Diagnostic
trouble code Occurrence judgment Recovery judgment trouble code Occurrence judgment Recovery judgment
Trouble location Trouble mode Judgment timing Prerequisites Trouble location Trouble mode Judgment timing Prerequisites
Dis- Dis-
DTC Conditions Conditions DTC Conditions Conditions
play play
Ground short/ Ground short/
Sensor; disconnection Voltage ≤ 0.25 V Sensor; disconnection Voltage ≤ 0.25 V
Immediately after Immediately after
Pressure 7000 O key switched ON None 0.25 V < Voltage < 4.75 V Pressure 7000 O key switched ON None 0.25 V < Voltage < 4.75 V
(P1) Power supply short Voltage ≥ 4.75 V (P1) Power supply short Voltage ≥ 4.75 V
Ground short/ Ground short/
Sensor; disconnection Voltage ≤ 0.25 V Sensor; disconnection Voltage ≤ 0.25 V
Immediately after Immediately after
Pressure 7001 O None 0.25 V < Voltage < 4.75 V Pressure 7001 O None 0.25 V < Voltage < 4.75 V
key switched ON key switched ON
(P2) Power supply short Voltage ≥ 4.75 V (P2) Power supply short Voltage ≥ 4.75 V
Ground short/ Ground short/
Sensor; disconnection Voltage ≤ 0.25 V Sensor; disconnection Voltage ≤ 0.25 V
Immediately after Immediately after
Pressure 7002 O None 0.25 V < Voltage < 4.75 V Pressure 7002 O None 0.25 V < Voltage < 4.75 V
key switched ON key switched ON
(N1) Power supply short Voltage ≥ 4.75 V (N1) Power supply short Voltage ≥ 4.75 V
Ground short/ Ground short/
Sensor; disconnection Voltage ≤ 0.25 V Sensor; disconnection Voltage ≤ 0.25 V
Immediately after Immediately after
Pressure 7003 O None 0.25 V < Voltage < 4.75 V Pressure 7003 O None 0.25 V < Voltage < 4.75 V
key switched ON key switched ON
(N2) Power supply short Voltage ≥ 4.75 V (N2) Power supply short Voltage ≥ 4.75 V
Ground short/ Ground short/
Sensor; disconnection Voltage ≤ 0.25 V Sensor; disconnection Voltage ≤ 0.25 V
Immediately after EU selected as Immediately after EU selected as
Pressure 7004 O 0.25 V < Voltage < 4.75 V Pressure 7004 O 0.25 V < Voltage < 4.75 V
key switched ON destination key switched ON destination
(Overload) Power supply short Voltage ≥ 4.75 V (Overload) Power supply short Voltage ≥ 4.75 V
Ground short/ Ground short/
Sensor; disconnection Voltage ≤ 0.25 V Sensor; disconnection Voltage ≤ 0.25 V
Immediately after Liftcrane Immediately after Liftcrane
Pressure 7005 O 0.25 V < Voltage < 4.75 V Pressure 7005 O 0.25 V < Voltage < 4.75 V
(Bottom) key switched ON selected (Bottom) key switched ON selected
Power supply short Voltage > 4.75 V Power supply short Voltage > 4.75 V
Ground short/ Ground short/
Sensor; disconnection Voltage ≤ 0.25 V Sensor; disconnection Voltage ≤ 0.25 V
Pressure 7006 O Immediately after Liftcrane 0.25 V < Voltage < 4.75 V Pressure 7006 O Immediately after Liftcrane 0.25 V < Voltage < 4.75 V
key switched ON selected key switched ON selected
(Rod) Power supply short Voltage ≥ 4.75 V (Rod) Power supply short Voltage ≥ 4.75 V
Ground short/ Ground short/
disconnection Voltage ≤ 0.25 V disconnection Voltage ≤ 0.25 V
Sensor; 7020 O Immediately after None 0.25 V < Voltage < 4.75 V Sensor; 7020 O Immediately after None 0.25 V < Voltage < 4.75 V
Pressure (Upper) key switched ON Pressure (Upper) key switched ON
Power supply short Voltage ≥ 4.75 V Power supply short Voltage ≥ 4.75 V
Ground short/ Ground short/
disconnection Voltage ≤ 0.25 V disconnection Voltage ≤ 0.25 V
Sensor; 7021 O Immediately after None 0.25 V < Voltage < 4.75 V Sensor; 7021 O Immediately after None 0.25 V < Voltage < 4.75 V
Pressure (Swing) key switched ON Pressure (Swing) key switched ON
Power supply short Voltage ≥ 4.75 V Power supply short Voltage ≥ 4.75 V
Ground short/ Ground short/
disconnection Voltage ≤ 0.25 V disconnection Voltage ≤ 0.25 V
Sensor; 7022 O Immediately after None 0.25 V < Voltage < 4.75 V Sensor; 7022 O Immediately after None 0.25 V < Voltage < 4.75 V
Pressure (Travel) key switched ON Pressure (Travel) key switched ON
Power supply short Voltage ≥ 4.75 V Power supply short Voltage ≥ 4.75 V

Disconnection Resistance ≥ 100 Ω Disconnection Resistance ≥ 100 Ω


Sensor; Immediately after Sensor; Immediately after
Fuel level
7040 O
key switched ON
None 2Ω < Resistance < 100Ω Fuel level
7040 O
key switched ON
None 2Ω < Resistance < 100Ω
Short Resistance ≤ 2 Ω Short Resistance ≤ 2 Ω

Resistance ≥ Resistance ≥
3 minutes after 3 minutes after
Sensor;
Disconnection
engine starts 67 200 Ω 111 Ω < Resistance < Sensor;
Disconnection
engine starts 67 200 Ω 111 Ω < Resistance <
Oil 7041 O None (Voltage ≥ 4.93 V ) 67 200 Ω Oil 7041 O None (Voltage ≥ 4.93 V ) 67 200 Ω
temperature
Immediately after Resistance ≤ 111 Ω (0.5 V < Voltage < 4.93 V) temperature
Immediately after Resistance ≤ 111 Ω (0.5 V < Voltage < 4.93 V)
Short Short
key switched ON (Voltage ≤ 0.5 V) key switched ON (Voltage ≤ 0.5 V)

Monitor Disconnection Monitor Disconnection


Immediately after Trouble bit received No trouble bit received from Immediately after Trouble bit received No trouble bit received from
thermistor 7045 X key switched ON None from monitor monitor thermistor 7045 X key switched ON None from monitor monitor
(*1) Short (*1) Short
From immediately From immediately
Pressure switch Disconnection 7063 O after key switched None Pressure switch = Pressure switch = ON Pressure switch Disconnection 7063 O after key switched None Pressure switch = Pressure switch = ON
return filter clog ON until engine OFF return filter clog ON until engine OFF
starts starts
(*1) Even if trouble occurs, the "ELEC. PROBLEM" message is not displayed. (*1) Even if trouble occurs, the "ELEC. PROBLEM" message is not displayed.
For items for which X is displayed, the “ELEC. PROBLEM” message is not displayed. Also, there is no DTC For items for which X is displayed, the “ELEC. PROBLEM” message is not displayed. Also, there is no DTC
display on the user screen. display on the user screen.
However, the DTC is recorded on the service (DIAG) screen. However, the DTC is recorded on the service (DIAG) screen.

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4001-128 4001-128

2) Electrical troubles (output) [7200-7399] 2) Electrical troubles (output) [7200-7399]

Diagnostic Occurrence judgment Recovery judgment Diagnostic Occurrence judgment Recovery judgment
trouble code trouble code
Trouble location Trouble mode Judgment timing Prerequisites Trouble location Trouble mode Judgment timing Prerequisites
Dis- Dis-
DTC play Conditions Conditions DTC play Conditions Conditions

Disconnection Disconnection
Solenoid;
7200 O
Immediately after
None Output ≠ Output = Output monitor
Solenoid;
7200 O
Immediately after
None Output ≠ Output = Output monitor
Swing brake key switched ON Output monitor Swing brake key switched ON Output monitor
Short Short

Solenoid; Disconnection Solenoid; Disconnection


Travel 7201 O
Immediately after
None Output ≠ Output = Output monitor Travel 7201 O
Immediately after
None Output ≠ Output = Output monitor
key switched ON Output monitor key switched ON Output monitor
high-speed Short high-speed Short

Disconnection Disconnection
Solenoid;
7202 O
Immediately after
None Output ≠ Output = Output monitor
Solenoid;
7202 O
Immediately after
None Output ≠ Output = Output monitor
Boost key switched ON Output monitor Boost key switched ON Output monitor
Short Short

Disconnection Disconnection
Travel alarm 7203 X Immediately after None Output ≠ Output = Output monitor Travel alarm 7203 X Immediately after None Output ≠ Output = Output monitor
buzzer(*1) key switched ON Output monitor buzzer(*1) key switched ON Output monitor
Short Short

Feed pump Disconnection Feed pump Disconnection


automatic stop 7205 O
Immediately after
None Output ≠ Output = Output monitor automatic stop 7205 O
Immediately after
None Output ≠ Output = Output monitor
relay key switched ON Output monitor relay key switched ON Output monitor
Short Short

Solenoid; Disconnection Solenoid; Disconnection


Option return 7206 O Immediately after None Output ≠ Output = Output monitor Option return 7206 O Immediately after None Output ≠ Output = Output monitor
key switched ON Output monitor key switched ON Output monitor
circuit Short circuit Short

Disconnection Disconnection
Solenoid;
7207 O
Immediately after
None Output ≠ Output = Output monitor
Solenoid;
7207 O
Immediately after
None Output ≠ Output = Output monitor
Free swing key switched ON Output monitor Free swing key switched ON Output monitor
Short Short

Disconnection Disconnection
Solenoid; 7208 O Immediately after None Output ≠ Output = Output monitor Solenoid; 7208 O Immediately after None Output ≠ Output = Output monitor
Fan reverse key switched ON Output monitor Fan reverse key switched ON Output monitor
Short Short

Air conditioner Disconnection Air conditioner Disconnection


coolant
7209 X
Immediately after
None Output ≠ Output = Output monitor
coolant
7209 X
Immediately after
None Output ≠ Output = Output monitor
temperature key switched ON Output monitor temperature key switched ON Output monitor
signal output (*1) Short signal output (*1) Short

Rotating light Disconnection Rotating light Disconnection


relay and bucket 7211 O
Immediately after
None Output ≠ Output = Output monitor relay and bucket 7211 O
Immediately after
None Output ≠ Output = Output monitor
lock key switched ON Output monitor lock key switched ON Output monitor
Short Short

Proportional Disconnection After engine starts Milli-amp ≤ 30 mA Proportional Disconnection After engine starts Milli-amp ≤ 30 mA
valve; valve;
7240 O None 30 mA < Milli-amp < 3 A 7240 O None 30 mA < Milli-amp < 3 A
Horsepower Immediately after Horsepower Immediately after
pump Short
key switched ON Milli-amp ≥ 3 A pump Short
key switched ON Milli-amp ≥ 3 A

Proportional Disconnection After engine starts Milli-amp ≤ 30 mA Proportional Disconnection After engine starts Milli-amp ≤ 30 mA
valve; 7241 O None 30 mA < Milli-amp < 3 A valve; 7241 O None 30 mA < Milli-amp < 3 A
Immediately after Immediately after
Pump flow Short
key switched ON Milli-amp ≥ 3 A Pump flow Short
key switched ON Milli-amp ≥ 3 A

(*1) Even if trouble occurs, the "ELEC. PROBLEM" message is not displayed. (*1) Even if trouble occurs, the "ELEC. PROBLEM" message is not displayed.
For items for which X is displayed, the “ELEC. PROBLEM” message is not displayed. Also, there is no DTC For items for which X is displayed, the “ELEC. PROBLEM” message is not displayed. Also, there is no DTC
display on the user screen. display on the user screen.
However, the DTC is recorded on the service (DIAG) screen. However, the DTC is recorded on the service (DIAG) screen.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-129 4001-129

3) Mechanical troubles [7400-7599] 3) Mechanical troubles [7400-7599]

Diagnostic Occurrence judgment Recovery judgment Diagnostic Occurrence judgment Recovery judgment
trouble code trouble code
Trouble location Trouble mode Judgment timing Prerequisites Trouble location Trouble mode Judgment timing Prerequisites
Dis- Dis-
DTC play Conditions Conditions DTC play Conditions Conditions
Coolant Coolant temperature Coolant temperature Coolant Coolant temperature Coolant temperature
Abnormally high temperature Abnormally high temperature
7400 O 7400 O
temperature 1 sensor = Normal ≥ 105°C (221°F) < 105°C (221°F) temperature 1 sensor = Normal ≥ 105°C (221°F) < 105°C (221°F)

CAN CAN
Coolant Abnormally high 1 minute after Coolant temperature Coolant temperature Coolant Abnormally high 1 minute after Coolant temperature Coolant temperature
7402 O communication 7402 O communication
temperature temperature 2 engine starts
= Normal ≥ 110°C (230°F) < 105°C (221°F) temperature temperature 2 engine starts
= Normal ≥ 110°C (230°F) < 105°C (221°F)
ECM 5 V power ECM 5 V power
Abnormally high supply voltage = Coolant temperature Coolant temperature Abnormally high supply voltage = Coolant temperature Coolant temperature
7403 O 7403 O
temperature 3 Normal ≥ 120°C (248°F) < 120°C (248°F) temperature 3 Normal ≥ 120°C (248°F) < 120°C (248°F)

Abnormally high 1 minute after Oil temperature Oil temperature Oil temperature Abnormally high 1 minute after Oil temperature Oil temperature Oil temperature
Oil temperature 7404 O Oil temperature 7404 O
temperature engine starts sensor = Normal ≥ 95°C (203°F) < 95°C (203°F) temperature engine starts sensor = Normal ≥ 95°C (203°F) < 95°C (203°F)
Boost Boost
temperature temperature
sensor = sensor =
Normal, Normal,
Abnormally high CAN Boost temperature Boost temperature Abnormally high CAN Boost temperature Boost temperature
7405 O 7405 O
Boost temperature 1 1 minute after communication ≥ 80°C (176°F) ≤ 70°C (158°F) Boost temperature 1 1 minute after communication ≥ 80°C (176°F) ≤ 70°C (158°F)
temperature engine starts = Normal, temperature engine starts = Normal,
ECM 5 V power ECM 5 V power
supply voltage = supply voltage =
Normal Normal
Abnormally high Boost temperature Boost temperature Abnormally high Boost temperature Boost temperature
7406 O 7406 O
temperature 2 ≥ 90°C (194°F) < 90°C (194°F) temperature 2 ≥ 90°C (194°F) < 90°C (194°F)
Abnormally low 10s after engine Generated voltage Abnormally low 10s after engine Generated voltage
Alternator voltage 7420 O None Generated voltage > 10 V Alternator voltage 7420 O None Generated voltage > 10 V
voltage starts ≤ 10 V voltage starts ≤ 10 V
Immediately after Immediately after
Coolant level Drop 7421 O None Level SW = ON Level SW = OFF Coolant level Drop 7421 O None Level SW = ON Level SW = OFF
key switched ON key switched ON
Oil pressure Oil pressure
sensor = sensor =
Normal, Normal,
CAN Pressure CAN Pressure
Engine oil Abnormally low 30s after engine Pressure Engine oil Abnormally low 30s after engine Pressure
7422 O communication 7422 O communication
pressure pressure starts = Normal, ≤ 40 kPa (5.8 PSI
> 40 40 kPa (5.8 PSI)
pressure pressure starts = Normal, ≤ 40 kPa (5.8 PSI
> 40 40 kPa (5.8 PSI)

ECM 5 V power ECM 5 V power


supply voltage = supply voltage =
Normal Normal
10s after engine 10s after engine
Air cleaner Clog 7423 O None Vacuum SW = ON Vacuum SW = OFF Air cleaner Clog 7423 O None Vacuum SW = ON Vacuum SW = OFF
starts starts
10s after engine Return filter 10s after engine Return filter
Return filter Clog 7424 O pressure switch Pressure SW = OFF Pressure SW = ON Return filter Clog 7424 O pressure switch Pressure SW = OFF Pressure SW = ON
starts = Normal starts = Normal

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


4001-130 4001-130

4) Faulty communication [7600-7799] 4) Faulty communication [7600-7799]

Diagnostic Occurrence Recovery judgment Diagnostic Occurrence Recovery judgment


trouble code judgment trouble code judgment
Trouble location Trouble mode Judgment timing Prerequisites Trouble location Trouble mode Judgment timing Prerequisites
Dis- Dis-
DTC play Conditions Conditions DTC play Conditions Conditions

Immediately after Bus off or error When the occurrence Immediately after Bus off or error When the occurrence
CAN bus Faulty bus 7600 O None CAN bus Faulty bus 7600 O None
key switched ON passive conditions are not met key switched ON passive conditions are not met

Faulty reception Packets not coming When the occurrence Faulty reception Packets not coming When the occurrence
from monitor conditions are not met from monitor conditions are not met
Communication 7601 O Immediately after None Reception from Communication 7601 O Immediately after None Reception from
monitor Faulty key switched ON monitor When the occurrence monitor Faulty key switched ON monitor When the occurrence
transmission Defective packet conditions are not met transmission Defective packet conditions are not met
received received
Communication Immediately after Messages not When the occurrence Communication Immediately after Messages not When the occurrence
ECM Time out 7602 O key switched ON None coming from ECM conditions are not met ECM Time out 7602 O key switched ON None coming from ECM conditions are not met
Liftcrane or Liftcrane or
Messages not Messages not
Communication Time out 7603 O Immediately after interference coming from When the occurrence Communication Time out 7603 O Immediately after interference coming from When the occurrence
computer S key switched ON prevention conditions are not met computer S key switched ON prevention conditions are not met
selected computer B selected computer B

Messages not Messages not


Communication Immediately after When the occurrence Communication Immediately after When the occurrence
computer B Time out 7604 O key switched ON None coming from conditions are not met computer B Time out 7604 O key switched ON None coming from conditions are not met
computer S computer S

ECM Mismatch 7605 O 10 s after engine Model selection Model ≠ ECM None. No recovery ECM Mismatch 7605 O 10 s after engine Model selection Model ≠ ECM None. No recovery
starts completed calibration No. starts completed calibration No.
Previously stored Previously stored
Previously stored Previously stored
EEPROM Faulty data 7606 X
Immediately after
None checksum ≠ checksum = EEPROM Faulty data 7606 X
Immediately after
None checksum ≠ checksum =
key switched ON Current calculated key switched ON Current calculated
Current calculated checksum Current calculated checksum
checksum checksum
For items for which X is displayed, the “ELEC. PROBLEM” message is not displayed. Also, there is no DTC For items for which X is displayed, the “ELEC. PROBLEM” message is not displayed. Also, there is no DTC
display on the user screen. display on the user screen.
However, the DTC is recorded on the service (DIAG) screen. However, the DTC is recorded on the service (DIAG) screen.

Lep SC130B4001-0EN Issued 11-07 Lep SC130B4001-0EN Issued 11-07


Section Section
4004 4004

4004

4004
REMOVAL AND INSTALLATION OF THE REMOVAL AND INSTALLATION OF THE
STARTER MOTOR STARTER MOTOR

Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B4004-0EN March 2008 CNH Lep SM130B4004-0EN March 2008
4004-2 4004-2
TABLE OF CONTENTS TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF STARTER MOTOR ..................................................................................... 3 REMOVAL AND INSTALLATION OF STARTER MOTOR ..................................................................................... 3
REMOVAL OF STARTER MOTOR .............................................................................................................................. 3 REMOVAL OF STARTER MOTOR .............................................................................................................................. 3
INSTALLATION OF STARTER MOTOR ........................................................................................................................ 4 INSTALLATION OF STARTER MOTOR ........................................................................................................................ 4

Lep SM130B4004-0EN Issued 03-08 Lep SM130B4004-0EN Issued 03-08


4004-3 4004-3
REMOVAL AND INSTALLATION OF STARTER MOTOR REMOVAL AND INSTALLATION OF STARTER MOTOR
Caution: Do not use open flames and do not allow sparks near the battery. Caution: Do not use open flames and do not allow sparks near the battery.

Caution: Be sure stop the engine before beginning work. Caution: Be sure stop the engine before beginning work.

1 Removal of starter motor 1 Removal of starter motor


[1] Use a wrench (17 mm) to remove the bolt (1), and [1] Use a wrench (17 mm) to remove the bolt (1), and
then remove the battery cable (2) on the negative then remove the battery cable (2) on the negative
side. 2 side. 2
• When removing the terminal and harness, secure • When removing the terminal and harness, secure
them so that they do not interfere with the frame. them so that they do not interfere with the frame.
Also, cover with a rubber cap to protect against Also, cover with a rubber cap to protect against
sparks. sparks.
1 1

NF11002-033 NF11002-033

[2] Use a wrench (8 mm) to remove the nut (3), and [2] Use a wrench (8 mm) to remove the nut (3), and
then remove the control signal wire (4). then remove the control signal wire (4).

3 3

4 4
NF11002-034 NF11002-034

[3] Remove the jump-start protector (5), use a wrench [3] Remove the jump-start protector (5), use a wrench
(14 mm) to remove the nut (6), and then disconnect (14 mm) to remove the nut (6), and then disconnect
the positive-side power (7) of the starter motor. the positive-side power (7) of the starter motor.
6 6
5 5

7 7

NF11002-035 NF11002-035

Lep SM130B4004-0EN Issued 03-08 Lep SM130B4004-0EN Issued 03-08


4004-4 4004-4
[4] Use a wrench (14 mm) to remove the bolt (8), and [4] Use a wrench (14 mm) to remove the bolt (8), and
then remove the wiring on the ground side (9). then remove the wiring on the ground side (9).

8 9 8 9
NF11002-036 NF11002-036

[5] Use a wrench (17 mm) to remove the nut (10), and [5] Use a wrench (17 mm) to remove the nut (10), and
then remove the starter motor (11). then remove the starter motor (11).
10 10

11 11
NF11002-037 NF11002-037

2 Installation of starter motor 2 Installation of starter motor


[1] To install, perform the reverse of the removal procedure. [1] To install, perform the reverse of the removal procedure.
Mount nut tightening torque: 82.4 Nm. Mount nut tightening torque: 82.4 Nm.

Lep SM130B4004-0EN Issued 03-08 Lep SM130B4004-0EN Issued 03-08


Section Section
4005 4005

REMOVAL AND INSTALLATION OF THE REMOVAL AND INSTALLATION OF THE


ALTERNATOR ALTERNATOR

4005

4005
Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B4005-0EN March 2008 CNH Lep SM130B4005-0EN March 2008
4005-2 4005-2
TABLE OF CONTENTS TABLE OF CONTENTS
REMOVAL AND INSTALLATION OF ALTERNATOR ........................................................................................... 3 REMOVAL AND INSTALLATION OF ALTERNATOR ........................................................................................... 3
REMOVAL OF ALTERNATOR.................................................................................................................................... 3 REMOVAL OF ALTERNATOR.................................................................................................................................... 3
INSTALLATION OF ALTERNATOR ............................................................................................................................. 4 INSTALLATION OF ALTERNATOR ............................................................................................................................. 4

Lep SM130B4005-0EN Issued 03-08 Lep SM130B4005-0EN Issued 03-08


4005-3 4005-3
REMOVAL AND INSTALLATION OF ALTERNATOR REMOVAL AND INSTALLATION OF ALTERNATOR
Caution: Do not use open flames and do not allow sparks near the battery. Caution: Do not use open flames and do not allow sparks near the battery.

Caution: Be sure stop the engine before beginning work. Caution: Be sure stop the engine before beginning work.

1 Removal of alternator 1 Removal of alternator


[1] Remove the fan belt. [1] Remove the fan belt.
(For details, see "Removal and Installation of Fan (For details, see "Removal and Installation of Fan
Belt".) Belt".)
2 2
[2] Use a wrench (17 mm) to remove the bolt (1), and [2] Use a wrench (17 mm) to remove the bolt (1), and
then remove the battery cable (2) on the negative then remove the battery cable (2) on the negative
side. side.
• When removing the terminal and harness, secure 1 • When removing the terminal and harness, secure 1
them so that they do not interfere with the frame. them so that they do not interfere with the frame.
Also, cover with a rubber cap to protect against Also, cover with a rubber cap to protect against
sparks. sparks.

NF11002-040 NF11002-040

[3] Remove the connector (3). [3] Remove the connector (3).

3 3

NF11002-041 NF11002-041

[4] Use a wrench (10 mm) to remove the bolt (4), and [4] Use a wrench (10 mm) to remove the bolt (4), and
then remove the wiring (5). then remove the wiring (5).

4 4
5 5

NF11002-042 NF11002-042

Lep SM130B4005-0EN Issued 03-08 Lep SM130B4005-0EN Issued 03-08


4005-4 4005-4
[5] Use a wrench (10 mm) to remove the nut (6), and [5] Use a wrench (10 mm) to remove the nut (6), and
then remove the wiring (5). then remove the wiring (5).
5 5

6 6

NF11002-043 NF11002-043

[6] Use a wrench (20 mm) to remove the bolt (7), and [6] Use a wrench (20 mm) to remove the bolt (7), and
then remove the alternator (8). then remove the alternator (8).

7 7

8 8

NF11002-044 NF11002-044

2 Installation of alternator 2 Installation of alternator


[1] To install, perform the reverse of the removal procedure. [1] To install, perform the reverse of the removal procedure.
Adjust the fan belt according to the tension adjustment procedure. Adjust the fan belt according to the tension adjustment procedure.

Lep SM130B4005-0EN Issued 03-08 Lep SM130B4005-0EN Issued 03-08


Section Section
4020 4020

ELECTRICAL EQUIPEMENT ELECTRICAL EQUIPEMENT


& &
ELECTRIC CIRCUIT DIAGRAMS ELECTRIC CIRCUIT DIAGRAMS

4020

4020
Copyright © 2007 CNH France S.A. Copyright © 2007 CNH France S.A.
Printed in France Printed in France
CNH Lep SC210B4020-1EN November 2007 CNH Lep SC210B4020-1EN November 2007
4020-2 4020-2
TABLE OF CONTENTS TABLE OF CONTENTS

ELECTRICAL EQUIPEMENT LAYOUT DIAGRAM ....................................................................................................... 4 ELECTRICAL EQUIPEMENT LAYOUT DIAGRAM ....................................................................................................... 4
Overall View ............................................................................................................................................................. 4 Overall View ............................................................................................................................................................. 4
Main Unit Right Side Layout Diagram (radiator compartment) ................................................................................. 8 Main Unit Right Side Layout Diagram (radiator compartment) ................................................................................. 8
Engine Section Layout Diagram ............................................................................................................................. 12 Engine Section Layout Diagram ............................................................................................................................. 12
Main Unit Left Side Layout Diagram (pump compartment) .................................................................................... 15 Main Unit Left Side Layout Diagram (pump compartment) .................................................................................... 15
Main Unit Center Section Layout Diagram ............................................................................................................. 19 Main Unit Center Section Layout Diagram ............................................................................................................. 19
Cab Layout Diagram 1 ........................................................................................................................................... 20 Cab Layout Diagram 1 ........................................................................................................................................... 20
Controller A ........................................................................................................................................................ 21 Controller A ........................................................................................................................................................ 21
Relay .................................................................................................................................................................. 21 Relay .................................................................................................................................................................. 21
ECM (engine control module) ............................................................................................................................ 21 ECM (engine control module) ............................................................................................................................ 21
Fuse box ............................................................................................................................................................ 21 Fuse box ............................................................................................................................................................ 21
Layout Around Operator Seat ................................................................................................................................ 22 Layout Around Operator Seat ................................................................................................................................ 22
Stand-Alone Parts Diagram ................................................................................................................................... 23 Stand-Alone Parts Diagram ................................................................................................................................... 23
Connection Connector Pin Layout ......................................................................................................................... 39 Connection Connector Pin Layout ......................................................................................................................... 39
Computer A ........................................................................................................................................................ 39 Computer A ........................................................................................................................................................ 39
Monitor ............................................................................................................................................................... 40 Monitor ............................................................................................................................................................... 40
ELECTRIC CIRCUIT DIAGRAM .................................................................................................................................. 42 ELECTRIC CIRCUIT DIAGRAM .................................................................................................................................. 42
List of components ................................................................................................................................................. 42 List of components ................................................................................................................................................. 42
Sequence Circuit Diagram (CX130B) ..................................................................................................................... 43 Sequence Circuit Diagram (CX130B) ..................................................................................................................... 43
Sequence Circuit Diagram (CX160B-CX180B) ...................................................................................................... 44 Sequence Circuit Diagram (CX160B-CX180B) ...................................................................................................... 44
Sequence Circuit Diagram (CX210B, CX230B, CX240B) ...................................................................................... 45 Sequence Circuit Diagram (CX210B, CX230B, CX240B) ...................................................................................... 45
Sequence Circuit Diagram (CX290B) ..................................................................................................................... 46 Sequence Circuit Diagram (CX290B) ..................................................................................................................... 46
BLOC DIAGRAM .................................................................................................................................................... 47 BLOC DIAGRAM .................................................................................................................................................... 47
Computer A ........................................................................................................................................................ 47 Computer A ........................................................................................................................................................ 47
Computer S ........................................................................................................................................................ 49 Computer S ........................................................................................................................................................ 49
ECM (Engine Control Module) (CX210B-CX230B-CX240B) ............................................................................. 50 ECM (Engine Control Module) (CX210B-CX230B-CX240B) ............................................................................. 50
ECM (Engine Control Module) (CX290B) .......................................................................................................... 51 ECM (Engine Control Module) (CX290B) .......................................................................................................... 51
Monitor Display .................................................................................................................................................. 52 Monitor Display .................................................................................................................................................. 52
Air Conditioner ................................................................................................................................................... 53 Air Conditioner ................................................................................................................................................... 53
Lever Lock .......................................................................................................................................................... 54 Lever Lock .......................................................................................................................................................... 54
Horn ................................................................................................................................................................... 54 Horn ................................................................................................................................................................... 54
Working Light ..................................................................................................................................................... 55 Working Light ..................................................................................................................................................... 55
Option ................................................................................................................................................................. 55 Option ................................................................................................................................................................. 55
Others ................................................................................................................................................................ 56 Others ................................................................................................................................................................ 56
Electrical Symbol List ......................................................................................................................................... 57 Electrical Symbol List ......................................................................................................................................... 57
ELECTRICAL CONNECTOR WIRING DIAGRAM ....................................................................................................... 59 ELECTRICAL CONNECTOR WIRING DIAGRAM ....................................................................................................... 59
Main Frame ............................................................................................................................................................ 59 Main Frame ............................................................................................................................................................ 59
Main Frame CX130B .......................................................................................................................................... 59 Main Frame CX130B .......................................................................................................................................... 59
Main Frame CX160B-CX180B ........................................................................................................................... 60 Main Frame CX160B-CX180B ........................................................................................................................... 60
Main Frame CX210B, CX230B, CX240B ........................................................................................................... 61 Main Frame CX210B, CX230B, CX240B ........................................................................................................... 61
Main Frame CX290B .......................................................................................................................................... 62 Main Frame CX290B .......................................................................................................................................... 62
Cab ......................................................................................................................................................................... 63 Cab ......................................................................................................................................................................... 63
Cab main harness (CX130B) ............................................................................................................................. 63 Cab main harness (CX130B) ............................................................................................................................. 63
Cab main harness (CX160B to CX290B) ........................................................................................................... 64 Cab main harness (CX160B to CX290B) ........................................................................................................... 64
Cab sub harness ................................................................................................................................................ 65 Cab sub harness ................................................................................................................................................ 65
In cab harness .................................................................................................................................................... 66 In cab harness .................................................................................................................................................... 66
Engine Harness ...................................................................................................................................................... 67 Engine Harness ...................................................................................................................................................... 67
CX130B .............................................................................................................................................................. 67 CX130B .............................................................................................................................................................. 67
CX160B, CX180B .............................................................................................................................................. 68 CX160B, CX180B .............................................................................................................................................. 68
CX210B, CX230B, CX240B ............................................................................................................................... 69 CX210B, CX230B, CX240B ............................................................................................................................... 69
CX290B .............................................................................................................................................................. 70 CX290B .............................................................................................................................................................. 70
Console .................................................................................................................................................................. 71 Console .................................................................................................................................................................. 71
Console Right harness ....................................................................................................................................... 71 Console Right harness ....................................................................................................................................... 71
Console Left harness ......................................................................................................................................... 71 Console Left harness ......................................................................................................................................... 71

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-3 4020-3

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-4 4020-4
ELECTRICAL EQUIPEMENT LAYOUT DIAGRAM ELECTRICAL EQUIPEMENT LAYOUT DIAGRAM
Overall View Overall View
a) CX130B a) CX130B

1 5 1 5

2 4 2 4

3 3

1 Main unit right side (radiator compartment) 1 Main unit right side (radiator compartment)
2 Engine 2 Engine
3 Main unit left side (pump compartment) 3 Main unit left side (pump compartment)
4 Main unit center section 4 Main unit center section
5 In cab 5 In cab

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-5 4020-5
b) CX160B, CX180B b) CX160B, CX180B

1 5 1 5

2 4 2 4

3 3

1 Main unit right side (radiator compartment) 1 Main unit right side (radiator compartment)
2 Engine 2 Engine
3 Main unit left side (pump compartment) 3 Main unit left side (pump compartment)
4 Main unit center section 4 Main unit center section
5 In cab 5 In cab

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-6 4020-6
c) CX210B, CX230B, CX240B c) CX210B, CX230B, CX240B

1 5 1 5

2 4 2 4

3 3

1 Main unit right side (radiator compartment) 1 Main unit right side (radiator compartment)
2 Engine 2 Engine
3 Main unit left side (pump compartment) 3 Main unit left side (pump compartment)
4 Main unit center section 4 Main unit center section
5 In cab 5 In cab

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-7 4020-7
d) CX290B d) CX290B

1 5 1 5

2 4 2 4

3 3

1 Main unit right side (radiator compartment) 1 Main unit right side (radiator compartment)
2 Engine 2 Engine
3 Main unit left side (pump compartment) 3 Main unit left side (pump compartment)
4 Main unit center section 4 Main unit center section
5 In cab 5 In cab

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-8 4020-8
1. Main Unit Right Side Layout Diagram (radiator compartment) 1. Main Unit Right Side Layout Diagram (radiator compartment)
a) CX130B a) CX130B

2 1 9 2 1 9

3 4 5 8 3 4 5 8

6 12 11 7 6 12 11 7

13 13

10 10

14 14

NE01005-002 NE01005-002

1 Air cleaner sensor 6 Fuse: ECM 20A (F4) 11 Safety relay 1 Air cleaner sensor 6 Fuse: ECM 20A (F4) 11 Safety relay
2 Suction air temperature sensor 7 Fuse: controller 20A (F5) 12 Battery relay 2 Suction air temperature sensor 7 Fuse: controller 20A (F5) 12 Battery relay
3 Fusible link 65A (F1) 8 Fuse: GPS 15A (F6) 13 Receiver dryer sensor 3 Fusible link 65A (F1) 8 Fuse: GPS 15A (F6) 13 Receiver dryer sensor
4 Fusible link 50A (F2) 9 Swing pilot pressure sensor 14 Battery 4 Fusible link 50A (F2) 9 Swing pilot pressure sensor 14 Battery
5 Fuse: key 15A (F3) 10 Washer motor 5 Fuse: key 15A (F3) 10 Washer motor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-9 4020-9
b) CX160B, CX180B b) CX160B, CX180B
2 1 9 2 1 9

5 8 5 8

4 4

3 3
11 11

12 12
6 7 6 7

14 14

13 13

10 10

LE01002-002 LE01002-002

1 Air cleaner sensor 6 Fuse: ECM 20A (F4) 11 Safety relay 1 Air cleaner sensor 6 Fuse: ECM 20A (F4) 11 Safety relay
2 Suction air temperature sensor 7 Fuse: controller 20A (F5) 12 Battery relay 2 Suction air temperature sensor 7 Fuse: controller 20A (F5) 12 Battery relay
3 Fusible link 65A (F1) 8 Fuse: GPS 15A (F6) 13 Receiver dryer sensor 3 Fusible link 65A (F1) 8 Fuse: GPS 15A (F6) 13 Receiver dryer sensor
4 Fusible link 50A (F2) 9 Swing pilot pressure sensor 14 Battery 4 Fusible link 50A (F2) 9 Swing pilot pressure sensor 14 Battery
5 Fuse: key 15A (F3) 10 Washer motor 5 Fuse: key 15A (F3) 10 Washer motor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-10 4020-10
c) CX210B, CX230B, CX240B c) CX210B, CX230B, CX240B
1 1

2 2

9 9

5 8 5 8

4 4

3 3

10 10
6 6

11 7 11 7

12 12

14 14

13 13

1 Air cleaner sensor 6 Fuse: ECM 20A (F4) 11 Safety relay 1 Air cleaner sensor 6 Fuse: ECM 20A (F4) 11 Safety relay
2 Suction air temperature sensor 7 Fuse: controller 20A (F5) 12 Battery relay 2 Suction air temperature sensor 7 Fuse: controller 20A (F5) 12 Battery relay
3 Fusible link 65A (F1) 8 Fuse: GPS 15A (F6) 13 Receiver dryer sensor 3 Fusible link 65A (F1) 8 Fuse: GPS 15A (F6) 13 Receiver dryer sensor
4 Fusible link 50A (F2) 9 Swing pilot pressure sensor 14 Battery 4 Fusible link 50A (F2) 9 Swing pilot pressure sensor 14 Battery
5 Fuse: key 15A (F3) 10 Washer motor 5 Fuse: key 15A (F3) 10 Washer motor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-11 4020-11
d) CX290B d) CX290B

5 5

8 9 8 9
4 4

7 10 7 10
3 3

6 6

14 14

12 12
13 13

11 11

1 1

2 2

BE01003-00 BE01003-00

1 Air cleaner sensor 6 Fuse: ECM 20A (F4) 11 Safety relay 1 Air cleaner sensor 6 Fuse: ECM 20A (F4) 11 Safety relay
2 Suction air temperature sensor 7 Fuse: controller 20A (F5) 12 Battery relay 2 Suction air temperature sensor 7 Fuse: controller 20A (F5) 12 Battery relay
3 Fusible link 65A (F1) 8 Fuse: GPS 15A (F6) 13 Receiver dryer sensor 3 Fusible link 65A (F1) 8 Fuse: GPS 15A (F6) 13 Receiver dryer sensor
4 Fusible link 50A (F2) 9 Swing pilot pressure sensor 14 Battery 4 Fusible link 50A (F2) 9 Swing pilot pressure sensor 14 Battery
5 Fuse: key 15A (F3) 10 Washer motor 5 Fuse: key 15A (F3) 10 Washer motor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-12 4020-12
2. Engine Section Layout Diagram 2. Engine Section Layout Diagram
a) CX130B, CX160B, CX180B a) CX130B, CX160B, CX180B

3 3
11 1 11 1

2 2

5 5

6 6

4 4

7 7

8 8

9 9

10 12 10 12

LE01002-003 LE01002-003

1 Engine coolant temperature sensor 7 Starter motor 1 Engine coolant temperature sensor 7 Starter motor
2 Boost pressure sensor 8 Engine coolant temperature sensor 2 Boost pressure sensor 8 Engine coolant temperature sensor
3 Overheat switch 9 Suction control valve 3 Overheat switch 9 Suction control valve
4 Common rail pressure sensor 10 Fuel temperature sensor 4 Common rail pressure sensor 10 Fuel temperature sensor
5 EGR valve 11 Cam position sensor 5 EGR valve 11 Cam position sensor
6 Boost temperature sensor 12 Crank position sensor 6 Boost temperature sensor 12 Crank position sensor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-13 4020-13
b) CX210B, CX230B, CX240B b) CX210B, CX230B, CX240B
2 2
1 1

4 4

5 5

3 3
6 6

10 10

8 8
7 7
9 9

12 12

11 11

1 Engine coolant temperature sensor 7 Starter motor 1 Engine coolant temperature sensor 7 Starter motor
2 Boost pressure sensor 8 Engine coolant temperature sensor 2 Boost pressure sensor 8 Engine coolant temperature sensor
3 Overheat switch 9 Suction control valve 3 Overheat switch 9 Suction control valve
4 Common rail pressure sensor 10 Fuel temperature sensor 4 Common rail pressure sensor 10 Fuel temperature sensor
5 EGR valve 11 Cam position sensor 5 EGR valve 11 Cam position sensor
6 Boost temperature sensor 12 Crank position sensor 6 Boost temperature sensor 12 Crank position sensor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-14 4020-14
c) CX290B c) CX290B

11 11

1 1

2 6 2 6

3 3
7 7

5 5

4 4

10 10
8 8

9 12 9 12

1 Engine coolant temperature sensor 7 Starter motor 1 Engine coolant temperature sensor 7 Starter motor
2 Boost pressure sensor 8 Engine coolant temperature sensor 2 Boost pressure sensor 8 Engine coolant temperature sensor
3 Overheat switch 9 Suction control valve 3 Overheat switch 9 Suction control valve
4 Common rail pressure sensor 10 Fuel temperature sensor 4 Common rail pressure sensor 10 Fuel temperature sensor
5 EGR valve 11 Cam position sensor 5 EGR valve 11 Cam position sensor
6 Boost temperature sensor 12 Crank position sensor 6 Boost temperature sensor 12 Crank position sensor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-15 4020-15
3. Main Unit Left Side Layout Diagram (pump compartment) 3. Main Unit Left Side Layout Diagram (pump compartment)
a) CX130B a) CX130B

1 1

2 2

3 3

4 4

5 7 5 7

6 8 6 8

9 9
11 11

12 12
10 10

13 13

NE01005-004 NE01005-004

1 Electromagnetic fuel pump 8 Travel speed (Y4) 1 Electromagnetic fuel pump 8 Travel speed (Y4)
2 P1 pressure sensor 9 N1 pressure sensor 2 P1 pressure sensor 9 N1 pressure sensor
3 P2 pressure sensor 10 P1 flow control proportional valve 3 P2 pressure sensor 10 P1 flow control proportional valve
4 4-way solenoid valve 11 Horsepower control proportional valve 4 4-way solenoid valve 11 Horsepower control proportional valve
5 Swing lock (Y3) 12 N2 pressure sensor 5 Swing lock (Y3) 12 N2 pressure sensor
6 Lever lock (Y2) 13 Oil temperature sensor 6 Lever lock (Y2) 13 Oil temperature sensor
7 Boosted pressure (Y5) 7 Boosted pressure (Y5)

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-16 4020-16
b) CX160B, CX180B b) CX160B, CX180B

1 1

2 2

3 3

4 4
7 7
5 8 5 8
6 9 6 9

10 12 10 12

13 13
11 11

14 14

LE01002-004 LE01002-004

1 Electromagnetic fuel pump 8 Power save 1 Electromagnetic fuel pump 8 Power save
2 P1 pressure sensor 9 Lever lock 2 P1 pressure sensor 9 Lever lock
3 P2 pressure sensor 10 N1 pressure sensor 3 P2 pressure sensor 10 N1 pressure sensor
4 5-way solenoid valve 11 P1 flow control proportional valve 4 5-way solenoid valve 11 P1 flow control proportional valve
5 Boosted pressure 12 Horsepower control proportional valve 5 Boosted pressure 12 Horsepower control proportional valve
6 Travel speed 13 N2 pressure sensor 6 Travel speed 13 N2 pressure sensor
7 Swing lock 14 Oil temperature sensor 7 Swing lock 14 Oil temperature sensor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-17 4020-17
c) CX210B, CX230B, CX240B c) CX210B, CX230B, CX240B

1 1

2 2

3 3

4 4

7 7
5 8 5 8
6 9 6 9
10 10

11 11

12 12

13 13

14 14

1 Electromagnetic fuel pump 8 Power save 1 Electromagnetic fuel pump 8 Power save
2 P1 pressure sensor 9 Lever lock 2 P1 pressure sensor 9 Lever lock
3 P2 pressure sensor 10 N1 pressure sensor 3 P2 pressure sensor 10 N1 pressure sensor
4 5-way solenoid valve 11 P1 flow control proportional valve 4 5-way solenoid valve 11 P1 flow control proportional valve
5 Boosted pressure 12 Horsepower control proportional valve 5 Boosted pressure 12 Horsepower control proportional valve
6 Travel speed 13 N2 pressure sensor 6 Travel speed 13 N2 pressure sensor
7 Swing lock 14 Oil temperature sensor 7 Swing lock 14 Oil temperature sensor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-18 4020-18
d) CX290B d) CX290B

2 2
1 1

4 4
3 3
7 7
5 8 5 8
6 9 6 9
10 10

13 13

11 11

12 12

14 14

BE01003-004 BE01003-004

1 Electromagnetic fuel pump 8 Power save 1 Electromagnetic fuel pump 8 Power save
2 P1 pressure sensor 9 Lever lock 2 P1 pressure sensor 9 Lever lock
3 P2 pressure sensor 10 N1 pressure sensor 3 P2 pressure sensor 10 N1 pressure sensor
4 5-way solenoid valve 11 P1 flow control proportional valve 4 5-way solenoid valve 11 P1 flow control proportional valve
5 Boosted pressure 12 Horsepower control proportional valve 5 Boosted pressure 12 Horsepower control proportional valve
6 Travel speed 13 N2 pressure sensor 6 Travel speed 13 N2 pressure sensor
7 Swing lock 14 Oil temperature sensor 7 Swing lock 14 Oil temperature sensor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-19 4020-19
4. Main Unit Center Section Layout Diagram 4. Main Unit Center Section Layout Diagram

CX130B CX160B, CX180B CX130B CX160B, CX180B

1 1

3 3

1 1
3 3

CX210B, CX230B, CX240B, CX290B CX210B, CX230B, CX240B, CX290B

1 1

2 2

3 3

1 Upper side pressure sensor 1 Upper side pressure sensor


2 Arm-in pressure sensor 2 Arm-in pressure sensor
3 Travel pressure sensor 3 Travel pressure sensor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-20 4020-20
5. Cab Layout Diagram 1 5. Cab Layout Diagram 1

1 Air conditioner solar radiation sensor 7 Monitor display 13 Air conditioner control panel 1 Air conditioner solar radiation sensor 7 Monitor display 13 Air conditioner control panel
2 Clock 8 12 V socket 14 Emergency stop switch 2 Clock 8 12 V socket 14 Emergency stop switch
3 Cigar lighter 9 Wiper motor 15 Rocker switch 3 Cigar lighter 9 Wiper motor 15 Rocker switch
4 Knob 10 Radio 16 Gate lock limit switch 4 Knob 10 Radio 16 Gate lock limit switch
5 Wiper controller 11 Throttle volume 5 Wiper controller 11 Throttle volume
6 Rocker switches (4) 12 Key cylinder 6 Rocker switches (4) 12 Key cylinder

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-21 4020-21

1 3 1 3

2 2

R1 R1
R3 R3
R2 R5 R2 R5
R4 R7 R4 R7
R6 R9 R6 R9
R8 R11 R8 R11
4 R10 4 R10
F7

F7
F8

F8
F10

F10
F9

F9
F11

F11
F12

F12
F13

F13
F14

F14
F15

F15
F16

F16
F17

F17
F18

F18
F19

F19
F20

F20
F21

F21
F22

F22
F23

F23
F24

F24
F25

F25
F26

F26
1) Controller A 1) Controller A
2) Relay 2) Relay
R1 Main relay R5 Horn relay L R9 Room lamp relay R1 Main relay R5 Horn relay L R9 Room lamp relay
R2 Glow relay R6 Horn relay R R10 Beacon relay R2 Glow relay R6 Horn relay R R10 Beacon relay
R3 Lamp relay R7 Speaker relay R R11 Starter cut relay R3 Lamp relay R7 Speaker relay R R11 Starter cut relay
R4 Lamp relay (CAB) R8 Speaker relay L R4 Lamp relay (CAB) R8 Speaker relay L
3) ECM (engine control module) 3) ECM (engine control module)
4) Fuse box 4) Fuse box
F7 Memory, cab light, car radio (10 A) F17 Fuel filler pump (20 A) F7 Memory, cab light, car radio (10 A) F17 Fuel filler pump (20 A)
F8 Engine pre-heating (30 A) F18 Clock (10 A) F8 Engine pre-heating (30 A) F18 Clock (10 A)
F9 Optional (10 A) F19 Cigarette lighter, operator’s seat (15 A) F9 Optional (10 A) F19 Cigarette lighter, operator’s seat (15 A)
F10 Air conditioning, heater (5 A) F20 DC rectifier (10 A) F10 Air conditioning, heater (5 A) F20 DC rectifier (10 A)
F11 Air conditioning condenser fan (15 A) F21 Rotating beacon / Travel Alarm (10 A) F11 Air conditioning condenser fan (15 A) F21 Rotating beacon / Travel Alarm (10 A)
F12 Air conditioning compressor (5 A) F22 Not used (15 A) F12 Air conditioning compressor (5 A) F22 Not used (15 A)
F13 Solenoid (10 A) F23 Fuel supply electric pump (10 A) F13 Solenoid (10 A) F23 Fuel supply electric pump (10 A)
F14 Windshield wiper/washer (15 A) F24 Not used (15 A) F14 Windshield wiper/washer (15 A) F24 Not used (15 A)
F15 Horn (10 A) F25 Hydraulic control cancellation (10 A) F15 Horn (10 A) F25 Hydraulic control cancellation (10 A)
F16 Cab light (15 A) F26 Working lights (15 A) F16 Cab light (15 A) F26 Working lights (15 A)

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-22 4020-22
6. Layout Around Operator Seat 6. Layout Around Operator Seat

1 1

9 9

5 5

7 5 7 5

6 6

3 2 3 2

3 3

8 8

4 4

10 10

1 Cup holder 1 Cup holder


2 Key switch 2 Key switch
3 Rocker switch base 3 Rocker switch base
4 AM / FM radio 4 AM / FM radio
5 Tilt lever 5 Tilt lever
6 Throttle volume 6 Throttle volume
7 Ashtray 7 Ashtray
8 Air conditioner control panel 8 Air conditioner control panel
9 Gate lever 9 Gate lever
10 Emergency stop switch 10 Emergency stop switch

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-23 4020-23
Stand-Alone Parts Diagram Stand-Alone Parts Diagram
Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Safety relay K8 Model: 24 V DC Safety relay K8 Model: 24 V DC

Battery relay K7 For +24 V DC Battery relay K7 For +24 V DC

Starter motor M1 CX210B model 5.0 kW-24 V Starter motor M1 CX210B model 5.0 kW-24 V

Alternator G2 CX210B model 50 A-24 V Alternator G2 CX210B model 50 A-24 V

Battery G1 Battery G1

Washer motor M4 Washer motor M4

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-24 4020-24

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Fusible link (F1) F1 Model: 65A Fusible link (F1) F1 Model: 65A

Fusible link (F2) F2 Model: 50A Fusible link (F2) F2 Model: 50A

Fuse box (F3, F3 Model: 20A & 15A Fuse box (F3, F3 Model: 20A & 15A
F4, F5, F6) F4, F5, F6)
F4 F4
F5 F5
F6 F6

Throttle volume R3 Throttle volume R3

Starter switch S1 Model: 24 V DC Starter switch S1 Model: 24 V DC

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-25 4020-25

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Fuel level sensor R5 Fuel level sensor R5

Electromagnetic M20 Model: 24 V DC Electromagnetic M20 Model: 24 V DC


pump pump

Reserve tank S55 Reserve tank S55


limit switch limit switch

Vacuum sensor S71 Vacuum sensor S71

Glow plug R1 Glow plug R1

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-26 4020-26

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
EGR motor M15 4JJ1 EGR motor M15 4JJ1
8 8
7 7
EGR position 6 EGR position 6
5 5
sensor B53 4 sensor B53 4
3 3
2 2
1 1

4HK1-6HK1 4HK1-6HK1
5 5
6 6
7 7
8 8
1 1
2 2
3 3
4 4

Common rail B52 Common rail B52


pressure sensor pressure sensor

Cam position B50 Cam position B50


sensor sensor
(4JJ1) VCC (4JJ1) VCC
OUT(PULSE) OUT(PULSE)
GND GND

Cam angle B50 Cam angle B50


sensor sensor
(4HK1-6HK1) (4HK1-6HK1)

Crank position B49 Crank position B49


sensor sensor
(4JJ1) VCC
(4JJ1) VCC
OUT(PULSE) OUT(PULSE)
GND GND

Crank angle B49 Crank angle B49


sensor sensor
(4HK1-6HK1) (4HK1-6HK1)

Oil pressure B21 Oil pressure B21


sensor sensor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-27 4020-27

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Boost pressure B47 Boost pressure B47
sensor sensor

Boost B51 Boost B51


temperature temperature
sensor sensor

Fuel B3 Fuel B3
temperature temperature
sensor sensor

Suction control Y35 Suction control Y35


valve valve
(4JJ1) (4JJ1)

Suction control Y35 Suction control Y35


valve valve
(4HK1-6HK1) (4HK1-6HK1)

Injector (4JJ1) (4HK1-6HK1)


Injector (4JJ1) (4HK1-6HK1)

Suction air B6 Suction air B6


temperature temperature
sensor sensor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-28 4020-28

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Engine coolant B1 Engine coolant B1
temperature temperature
sensor sensor

Atmospheric B48 Atmospheric B48


pressure sensor pressure sensor

Computer A A1 Computer A A1

Relay R Model: Relay R Model:


24 V DC 24 V DC

DC-DC U1 DC-DC U1
converter converter

Alarm B82 Alarm B82


(feed pump) (feed pump)

Feed pump M14 Feed pump M14

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-29 4020-29

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Feed pump S61 Feed pump S61
switch switch

Lamp (right side E1 Model: Lamp (right side E1 Model:


housing) 24 V 70 W housing) 24 V 70 W

Lamp (boom) E2 Model: Lamp (boom) E2 Model:


24 V 70 W 24 V 70 W

Lamp (cab top) E3 Model: Lamp (cab top) E3 Model:


24 V 70 W 24 V 70 W

Speakers Speakers
(R & L) (R & L)

Monitor display P4 Monitor display P4

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-30 4020-30

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Pressure B42 Model: Pressure B42 Model:
sensors B44 50.0 MPa sensors B44 50.0 MPa
(P1) (P2) (P1) (P2)

Pressure Model: Pressure Model:


sensors 5.0 MPa sensors 5.0 MPa
(N1) (N2) B43 (N1) (N2) B43
(swing) B40 (swing) B40
(upper side) B22 (upper side) B22
(travel) (arm-in) B26 (travel) (arm-in) B26
B27 B27
B33 B33
Pressure switch B28 Model: Pressure switch B28 Model:
(option) 0.49 MPa (option) 0.49 MPa
(second option) (second option)

Pressure switch S61 Pressure switch S61


(filter) (filter)

4-way solenoid Y2 CX130B model


4-way solenoid Y2 CX130B model
valve valve
Y3 Y3
Y4 Y4
Y5 Y5

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-31 4020-31

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
5-way solenoid Y2 5-way solenoid Y2
valve valve
Y3 Y3
Y4 Y4
Y5 Y5
Y6 Y6

2-way solenoid Y9 2-way solenoid Y9


valve (knob valve (knob
Y27 Y27
switch type) switch type)

2-way solenoid Y9 2-way solenoid Y9


valve (pedal valve (pedal
Y27 Y27
type) type)

P1 flow control Y11 P1 flow control Y11


proportional proportional
valve valve

Horsepower Y7 Horsepower Y7
control control
proportional proportional
valve valve

Free swing S22 Nor th America Free swing S22 Nor th America
switch Only switch Only

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-32 4020-32

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
CAB seat air X6 CAB seat air X6
suspension suspension
connector connector

Free swing Y18 Nor th America Free swing Y18 Nor th America
solenoid Only solenoid Only

( CX130B/CX160/210/240B)(CN.134)

( CX130B/CX160/210/240B)(CN.134)
(CX290B)(CN.133)

(CX290B)(CN.133)
Hydraulic oil B2 Hydraulic oil B2
temperature temperature
sensor sensor

Clock P9 Clock P9

Knob right (with P3 Model: Knob right (with P3 Model:


one-touch with two switches one-touch with two switches
switch) switch)

Knob right (with P3 Model: Knob right (with P3 Model:


one-touch with four switches one-touch with four switches
switch) switch)
(short type) (short type)

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-33 4020-33

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Knob left (with P2 Model: Knob left (with P2 Model:
horn switch and with two switches horn switch and with two switches
radio mute) radio mute)

Knob left (with P2 Model: Knob left (with P2 Model:


horn switch and with four switches horn switch and with four switches
radio mute) radio mute)
(short type) (short type)

Travel alarm H2 Basic frequency: Travel alarm H2 Basic frequency:


2560 Hz 2560 Hz
Nor th Amecrica Nor th Amecrica
only only

Horn (low) B81 Basic frequency: Horn (low) B81 Basic frequency:
370 Hz 370 Hz

Horn (high) B81 Basic frequency: Horn (high) B81 Basic frequency:
415 Hz 415 Hz

Diode (washer M4 Diode (washer M4


motor) motor)

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-34 4020-34

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Lever lock limit S51 Lever lock limit S51
switch switch

Radio connector X8 Radio connector X8

Lamp E4 Model: 24 V, 10 W Lamp E4 Model: 24 V, 10 W


(room lamp) (room lamp)

Accessory X15 Model: 12 V DC Accessory X15 Model: 12 V DC


socket socket

Cigar lighter E51 Model: 24V Cigar lighter E51 Model: 24V

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-35 4020-35

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Air conditioner E52 Air conditioner E52
unit unit

Limit switch S54 Limit switch S54


(front window) (front window)
(door) (door)

Wiper controller A4 Wiper controller A4

Wiper motor M3 Wiper motor M3

Solar radiation B61 Solar radiation B61


sensor sensor

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-36 4020-36

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Receiver drier S52 Receiver drier S52
(switch) (switch)

Air conditioner Y8 Air conditioner Y8


compressor compressor
(magnetic (magnetic
clutch) clutch)

Motor actuator M5 Motor actuator M5


(air mix) (mode) (air mix) (mode)
(recycle / (recycle /
refresh) refresh)

Evaporator B5 Evaporator B5
sensor sensor

Interior R4 Interior R4
temperature temperature
sensor sensor

Relay K17 Relay K17


(compressor) (compressor)
(blower OFF) (blower OFF)

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-37 4020-37

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Blower motor M8 Blower motor M8

Blower amp A6 Blower amp A6

Air conditioner P6 Air conditioner P6


switch panel switch panel

Option select S14 Option select S14


switch (breaker / switch (breaker /
crusher) crusher)

Option select Option select


switch (breaker) switch (breaker)

Option select Option select


switch (crusher) switch (crusher)

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-38 4020-38

Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
2nd speed S35 2nd speed S35
merge select merge select
switch (2 pumps switch (2 pumps
flow) flow)

Emergency stop S9 Emergency stop S9


switch switch

Over load S13 Europe Only Over load S13 Europe Only
warning warning

Travel alarm S28 Nor th America Travel alarm S28 Nor th America
switch Only switch Only

Beacon switch S6 Europe Only Beacon switch S6 Europe Only

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-39 4020-39
Connection Connector Pin Layout Connection Connector Pin Layout
1) Computer A 1) Computer A

1PIN 12PIN 1PIN 12PIN

CN. C4

CN. C4
11PIN 22PIN 11PIN 22PIN

1PIN 7PIN 1PIN 7PIN

CN. C3

CN. C3
6PIN 12PIN 6PIN 12PIN
1PIN 9PIN 1PIN 9PIN

CN. C2

CN. C2
8PIN 16PIN 8PIN 16PIN

1PIN 14PIN 1PIN 14PIN

CN. C1

CN. C1
13PIN 26PIN 13PIN 26PIN

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-40 4020-40
2) Monitor 2) Monitor

9PIN 20PIN 9PIN 20PIN

1PIN 10PIN 1PIN 10PIN

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-41 4020-41

This page is left blank intentionally This page is left blank intentionally

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-42 4020-42
ELECTRIC CIRCUIT DIAGRAM ELECTRIC CIRCUIT DIAGRAM
List of components List of components
(AS SHOWN ON THE FOLLOWING DIAGRAMS) K17 BLOWER OFF RELAY (AS SHOWN ON THE FOLLOWING DIAGRAMS) K17 BLOWER OFF RELAY
A1 COMPUTER K30 REFUEL PUMP RELAY A1 COMPUTER K30 REFUEL PUMP RELAY
A2 ENGINE CONTROLLER K31 REFUEL PUMP STOP RELAY A2 ENGINE CONTROLLER K31 REFUEL PUMP STOP RELAY
A4 WIPER CONTROLLER K33 MAIN RELAY A4 WIPER CONTROLLER K33 MAIN RELAY
A6 BLOWER CONTROLLER K34 RELAY STARTER CUT A6 BLOWER CONTROLLER K34 RELAY STARTER CUT
A9 AIR CONDITIONER CONTROLLER K35 RELAY ROOM LAMP A9 AIR CONDITIONER CONTROLLER K35 RELAY ROOM LAMP
B1 COOLANT TEMPERATURE SENSOR K36 RELAY SPEAKER LEFT B1 COOLANT TEMPERATURE SENSOR K36 RELAY SPEAKER LEFT
B2 HYDRAULIC OIL TEMPERATURE SENSOR K37 RELAY SPEAKER RIGHT B2 HYDRAULIC OIL TEMPERATURE SENSOR K37 RELAY SPEAKER RIGHT
B3 FUEL TEMPERATURE SENSOR K38 RELAY HORN LEFT B3 FUEL TEMPERATURE SENSOR K38 RELAY HORN LEFT
B5 EVAPORATOR SENSOR K39 RELAY HORN RIGHT B5 EVAPORATOR SENSOR K39 RELAY HORN RIGHT
B6 AIR INTAKE TEMPERATURE SENSOR M1 STARTER MOTOR B6 AIR INTAKE TEMPERATURE SENSOR M1 STARTER MOTOR
B21 ENGINE OIL PRESSURE SWITCH M3 WIPER MOTOR B21 ENGINE OIL PRESSURE SWITCH M3 WIPER MOTOR
B22 SWING PILOT PRESSURE SWITCH M4 WASHER MOTOR B22 SWING PILOT PRESSURE SWITCH M4 WASHER MOTOR
B23 BREAKER / CRUSHER PILOT PRESSURE SWITCH M5 MOTOR (AIR CHANGING) B23 BREAKER / CRUSHER PILOT PRESSURE SWITCH M5 MOTOR (AIR CHANGING)
B26 UPPER PILOT PRESSURE SENSOR M6 AIR VENT DIRECTION CONTROL MOTOR B26 UPPER PILOT PRESSURE SENSOR M6 AIR VENT DIRECTION CONTROL MOTOR
B27 TRAVEL PILOT PRESSURE SENSOR M7 MOTOR ACT (AIR-MIX) B27 TRAVEL PILOT PRESSURE SENSOR M7 MOTOR ACT (AIR-MIX)
B33 ARM CLOSE PRESS. SENSOR (CX210B TO CX290B) M8 BLOWER MOTOR B33 ARM CLOSE PRESS. SENSOR (CX210B TO CX290B) M8 BLOWER MOTOR
B42 PUMP PRESSURE SENSOR (P1) M14 FUEL FEED PUMP MOTOR B42 PUMP PRESSURE SENSOR (P1) M14 FUEL FEED PUMP MOTOR
B43 PRESSURE SENSOR (NEGA-CONT) M15 EXHAUST GAS RECIRCULATION MOTOR B43 PRESSURE SENSOR (NEGA-CONT) M15 EXHAUST GAS RECIRCULATION MOTOR
B44 PUMP PRESSURE SENSOR (P2) (BLUE BAND) P1 INSTRUMENT PANEL B44 PUMP PRESSURE SENSOR (P2) (BLUE BAND) P1 INSTRUMENT PANEL
B45 OVERLOAD INDICATOR PRESSURE SWITCH P5 HOURMETER B45 OVERLOAD INDICATOR PRESSURE SWITCH P5 HOURMETER
B47 BOOST PRESSURE SENSOR P6 AIR CONDITIONER CONTROL PANEL B47 BOOST PRESSURE SENSOR P6 AIR CONDITIONER CONTROL PANEL
B48 AMBIENT AIR (BAROMETRIC) PRESSURE SENSOR P9 CLOCK B48 AMBIENT AIR (BAROMETRIC) PRESSURE SENSOR P9 CLOCK
B49 CRANKSHAFT POSITION SENSOR R1 GLOW PLUG B49 CRANKSHAFT POSITION SENSOR R1 GLOW PLUG
B50 CAMSHAFT POSITION SENSOR R3 THROTTLE VOLUME B50 CAMSHAFT POSITION SENSOR R3 THROTTLE VOLUME
B51 BOOST TEMPERATURE SENSOR R4 THERMISTOR INNER TEMPERATURE B51 BOOST TEMPERATURE SENSOR R4 THERMISTOR INNER TEMPERATURE
B52 COMMON RAIL PRESSURE SENSOR R5 FUEL SENSOR B52 COMMON RAIL PRESSURE SENSOR R5 FUEL SENSOR
B53 EXHAUST GAS RECIRCULATION VALVE POSITION S1 KEY SWITCH B53 EXHAUST GAS RECIRCULATION VALVE POSITION S1 KEY SWITCH
SENSOR S9 ENGINE EMERGENCY STOP SWITCH SENSOR S9 ENGINE EMERGENCY STOP SWITCH
B61 SUNLOAD SENSOR S13 OVERLOAD SWITCH (EUROPE) B61 SUNLOAD SENSOR S13 OVERLOAD SWITCH (EUROPE)
E1 WORKING LIGHT (UPPERSTRUCTURE) S14 BREAKER / CRUSHER SWITCH E1 WORKING LIGHT (UPPERSTRUCTURE) S14 BREAKER / CRUSHER SWITCH
E2 WORKING LIGHT (ATTACHMENT) S15 HORN SWITCH E2 WORKING LIGHT (ATTACHMENT) S15 HORN SWITCH
E3 WORKING LIGHT (CAB) S16 ONE TOUCH IDLE E3 WORKING LIGHT (CAB) S16 ONE TOUCH IDLE
E4 CAB LIGHT S31 OPTION 1 SOLENOID VALVE SWITCH (NORTH AMERICA) E4 CAB LIGHT S31 OPTION 1 SOLENOID VALVE SWITCH (NORTH AMERICA)
E51 CIGARETTE LIGHTER S32 OPTION 1 SOLENOID VALVE SWITCH (NORTH AMERICA) E51 CIGARETTE LIGHTER S32 OPTION 1 SOLENOID VALVE SWITCH (NORTH AMERICA)
F1 FUSE 65A; MAIN FUSE FOR F8 TO F26 S33 OPTION 2 SOLENOID VALVE SWITCH F1 FUSE 65A; MAIN FUSE FOR F8 TO F26 S33 OPTION 2 SOLENOID VALVE SWITCH
F2 FUSE 50A; MAIN FUSE FOR F1 S34 OPTION 2 SOLENOID VALVE SWITCH F2 FUSE 50A; MAIN FUSE FOR F1 S34 OPTION 2 SOLENOID VALVE SWITCH
F3 FUSE 15A; KEY SWITCH AND MAIN FUSE FOR F7 S35 CRUSHER OPTION TWO FLOW SOLENOID VALVE F3 FUSE 15A; KEY SWITCH AND MAIN FUSE FOR F7 S35 CRUSHER OPTION TWO FLOW SOLENOID VALVE
F4 FUSE 20A; MAIN RELAY AND ENGINE STOP SWITCH F4 FUSE 20A; MAIN RELAY AND ENGINE STOP SWITCH
F5 FUSE 20A; COMPUTEUR CONTROL AND INSTRUMENT S51 HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH F5 FUSE 20A; COMPUTEUR CONTROL AND INSTRUMENT S51 HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
PANEL S52 AIR CONDITIONING COMPRESSOR CLUTCH SWITCH PANEL S52 AIR CONDITIONING COMPRESSOR CLUTCH SWITCH
F6 FUSE 15A; CONTROLLER S S54 FRONT WINDOW LIMIT SWITCH F6 FUSE 15A; CONTROLLER S S54 FRONT WINDOW LIMIT SWITCH
F7 FUSE 10A; MEMORY, CAB LIGHT, RADIO S55 RESERVE TANK LOW SWITCH F7 FUSE 10A; MEMORY, CAB LIGHT, RADIO S55 RESERVE TANK LOW SWITCH
F8 FUSE 30A; ENGINE PRE-HEATING S61 REFUEL PUMP SWITCH F8 FUSE 30A; ENGINE PRE-HEATING S61 REFUEL PUMP SWITCH
F9 FUSE 10A; OPTION LINE S62 AIR CLEANER SENSOR F9 FUSE 10A; OPTION LINE S62 AIR CLEANER SENSOR
F10 FUSE 5A; AIR CONDITIONER HEATER UNIT S69 RADIO MUTE SWITCH F10 FUSE 5A; AIR CONDITIONER HEATER UNIT S69 RADIO MUTE SWITCH
F11 FUSE 15A; AIR CONDITIONER BLOWER S71 PRESSURE SWITCH FILTER INDICATOR (HAMMER) F11 FUSE 15A; AIR CONDITIONER BLOWER S71 PRESSURE SWITCH FILTER INDICATOR (HAMMER)
F12 FUSE 5A; AIR CONDITIONER COMPRESSOR U1 DC-DC (24V-12V) CONVERTER F12 FUSE 5A; AIR CONDITIONER COMPRESSOR U1 DC-DC (24V-12V) CONVERTER
F13 FUSE 10A; SOLENOID X2 ROTARY LIGHT CONNECTOR (EUROPE) F13 FUSE 10A; SOLENOID X2 ROTARY LIGHT CONNECTOR (EUROPE)
F14 FUSE 15A; WINDSHIELD WIPER / WASHER X4 ENGINE TEST POINT CONNECTOR F14 FUSE 15A; WINDSHIELD WIPER / WASHER X4 ENGINE TEST POINT CONNECTOR
F15 FUSE 10A; HORN X5 CONTROLLER TEST POINT CONNECTOR F15 FUSE 10A; HORN X5 CONTROLLER TEST POINT CONNECTOR
F16 FUSE 15A; LAMP (BOOM, HOUSE) X6 CAB SEATCOMPRESSOR MOTOR CONNECTOR F16 FUSE 15A; LAMP (BOOM, HOUSE) X6 CAB SEATCOMPRESSOR MOTOR CONNECTOR
F17 FUSE 20A; FUEL FILLER PUMP X8 RADIO CONNECTOR F17 FUSE 20A; FUEL FILLER PUMP X8 RADIO CONNECTOR
F18 FUSE 10A; CLOCK, BACK MONITOR X9 ANTI-THEFT SYSTEM CONNETOR F18 FUSE 10A; CLOCK, BACK MONITOR X9 ANTI-THEFT SYSTEM CONNETOR
F19 FUSE 15A; CIGAR. LIGHTER, CAB SEAT X15 ACCESSORY SOCKET F19 FUSE 15A; CIGAR. LIGHTER, CAB SEAT X15 ACCESSORY SOCKET
F20 FUSE 10A; DC /DC CONVERTER X23 CLEAR MEMORY 1 F20 FUSE 10A; DC /DC CONVERTER X23 CLEAR MEMORY 1
F21 FUSE 10A; TRAVEL ALARM / BEACON Y2 PILOT PRESSURE SOLENOID VALVE (BLUE BAND) F21 FUSE 10A; TRAVEL ALARM / BEACON Y2 PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
F22 FUSE 15A; SPARE Y3 SWING BRAKE SOLENOID VALVE (WHITE BAND) F22 FUSE 15A; SPARE Y3 SWING BRAKE SOLENOID VALVE (WHITE BAND)
F23 FUSE 10A; FUEL SUPPLY PUMP Y4 2 STAGE TRAVEL SOLENOID VALVE (RED BAND) F23 FUSE 10A; FUEL SUPPLY PUMP Y4 2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
F24 FUSE 15A; SPARE Y5 POWER-UP SOLENOID VALVE (YELLOW BAND) F24 FUSE 15A; SPARE Y5 POWER-UP SOLENOID VALVE (YELLOW BAND)
F25 FUSE 10A; LEVER LOCK (GATE) Y6 POWER SAVE SOLENOID VALVE (GREEN BAND) F25 FUSE 10A; LEVER LOCK (GATE) Y6 POWER SAVE SOLENOID VALVE (GREEN BAND)
F26 FUSE 15A; LAMP (CAB) Y7 MAIN PUMP POWER PROPORTIONAL SOLENOID F26 FUSE 15A; LAMP (CAB) Y7 MAIN PUMP POWER PROPORTIONAL SOLENOID
G1 BATTERY Y8 AIR CONDITIONER MAGNET CLUTCH G1 BATTERY Y8 AIR CONDITIONER MAGNET CLUTCH
G2 ALTERNATOR Y9 CRUSHER OPTION TWO FLOW SOLENOID VALVE G2 ALTERNATOR Y9 CRUSHER OPTION TWO FLOW SOLENOID VALVE
H1 AUDIBLE WARNING DEVICE Y11 MAIN PUMP FLOW PROPORTIONAL SOLENOID H1 AUDIBLE WARNING DEVICE Y11 MAIN PUMP FLOW PROPORTIONAL SOLENOID
H2 TRAVEL ALARM (NORTH AMERICA) Y18 FREE SWING SOLENOID VALVE (NORTH AMERICA) H2 TRAVEL ALARM (NORTH AMERICA) Y18 FREE SWING SOLENOID VALVE (NORTH AMERICA)
K2 RELAY-GLOW PLUG Y23 OPTION 1 SOLENOID VALVE (NORTH AMERICA) K2 RELAY-GLOW PLUG Y23 OPTION 1 SOLENOID VALVE (NORTH AMERICA)
K5 RELAY-ROTARY LIGHT (EUROPE) Y24 OPTION 1 SOLENOID VALVE (NORTH AMERICA) K5 RELAY-ROTARY LIGHT (EUROPE) Y24 OPTION 1 SOLENOID VALVE (NORTH AMERICA)
K6 RELAY-AIR CONDITIONER CONDENSER FAN Y25 OPTION 2 SOLENOID VALVE (RED TAPE) K6 RELAY-AIR CONDITIONER CONDENSER FAN Y25 OPTION 2 SOLENOID VALVE (RED TAPE)
K8 RELAY SAFETY Y26 OPTION 2 SOLENOID VALVE (BLUE BAND) K8 RELAY SAFETY Y26 OPTION 2 SOLENOID VALVE (BLUE BAND)
K10 RELAY-WORKING LIGHT (UPPERSTRUCTURE / Y27 HAMMER RETURN CIRCUIT SOLENOID VALVE K10 RELAY-WORKING LIGHT (UPPERSTRUCTURE / Y27 HAMMER RETURN CIRCUIT SOLENOID VALVE
ATTACHMENT) Y35 SUCTION CONTROL VALVE (SCV) ATTACHMENT) Y35 SUCTION CONTROL VALVE (SCV)
K11 RELAY-WORKING LIGHT (CAB) K11 RELAY-WORKING LIGHT (CAB)

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-49 4020-49
2) Computer S 2) Computer S

Computer S Computer S

F6 15A RB145
F6 15A RB145
CNC6-1 CNC6-1
RB CNC6-2 RB CNC6-2

CNC6-12 B CNC6-12 B
B B
CNC6-13 CNC6-13

LgR530 LgR533 LgR530 LgR533


M CNC6-7 M CNC6-7

CN54 CN54
GW070 GW070
CN54-2 CNC7-6 CN54-2 CNC7-6
YR074 YR074
CN54-8 CNC7-4 CN54-8 CNC7-4
GL071 GL071
CN54-3 CNC7-14 CN54-3 CNC7-14
YL075 YL075
CN54-9 CNC7-13 CN54-9 CNC7-13

Computer A Computer A
PG041 PG041
A1 CNC2-14 A1 CNC2-14

Computer B Computer B
PG047 PG049 PG047 PG049
CNCR2-14 CNC7-16 CNCR2-14 CNC7-16

PG051 PG051
CNA0-23 CNA0-23

Computer A Computer A
P040 P040
A1 CNC2-6 A1 CNC2-6

Computer B Computer B
P044 PG049 P044 PG049
CNCR2-6 CNC7-16 CNCR2-6 CNC7-16

P042 P042
CNA0-18 CNA0-18

RE03003-003 RE03003-003

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-50 4020-50
3) ECM (Engine Control Module) (CX210B-CX230B-CX240B) 3) ECM (Engine Control Module) (CX210B-CX230B-CX240B)

KEY S/W K2 ECM A2 KEY S/W K2 ECM A2


S1 M ST
LgR530 LR336 24 107 L371 S1 M ST
LgR530 LR336 24 107 L371

Glow relay 106


G372 CKP sensor B49 Glow relay 106
G372 CKP sensor B49
BrR339 BW689 BrR339 BW689
R2 10 108 R2 10 108
R11 R11
GrR009 GrR010 GrR337 99 W373 GrR009 GrR010 GrR337 99 W373
46 46
98
L374 CMP sensor B50 98
L374 CMP sensor B50
BL687 BL687
100 100
Main relay Main relay
YR332 87 W307 YR332 87 W307
K33 R1 21
L317 Common rail K33 R1 21
L317 Common rail
YR333 YR333
40 82
L318
pressure sensor B52 40 82
L318
pressure sensor B52
90 90
F4 R1 F4 R1
RG125 WR330 G327 RG125 WR330 G327
2 101 2 101
WR331 5 WR331 5
94 GB363 U 94 GB363 U
Engine stop S / W 93 GW364
V
EGR position sensor B53 Engine stop S / W 93 GW364
V
EGR position sensor B53
S9 RG126 LG340
47 92 GR365
W S9 RG126 LG340
47 92 GR365
W

111 WR360 U 111 WR360 U


DIAGNOSTIC Connector 103 WB361 V M EGR valve M15 DIAGNOSTIC Connector 103 WB361 V M EGR valve M15
X4 CN51
110 WL362 motor X4 CN51
110 WL362 motor
W W

BG691 DIAG S/W PB083 PB082 WB303 BG691 DIAG S/W PB083 PB082 WB303
52 80 52 80

67
Y313 Oil pressure B21 67
Y313 Oil pressure B21
MEMORY CLEAR BY323 sensor MEMORY CLEAR BY323 sensor
BG692 BrY084 79 BG692 BrY084 79
X23 32 X23 32
84
RG316 BY Coolant temperature B1 84
RG316 BY Coolant temperature B1
sensor sensor
83 YG315 BY Fuel temperature 83 YG315 BY Fuel temperature
sensor B3 sensor B3
RW304 RW304
95 95

91 L314 Boost 91 L314 Boost


Computer A pressure sensor B47 Computer A pressure sensor B47
GW324 GW324
109 109
GR312 RL GR312 RL
A1 P040 P042 74 Boost temperature sensor B51 A1 P040 P042 74 Boost temperature sensor B51
CNC2-6 18 CNC2-6 18
PG041 PG043 RW368 PG041 PG043 RW368
CNC2-14 37 105 CNC2-14 37 105
SCV (suction SCV (suction
113 RW369
control valve) Y35 113 RW369
control valve) Y35
89 RG366 89 RG366

97 RG367 97 RG367

W350 Injector #1 W350 Injector #1


121 121
L352 L352
119 119

Injector #2 Injector #2
BARO 118
P355 BARO 118
P355
(atmospheric pressure) (atmospheric pressure)
sensor sensor
W300 W300
61 61
R351 Injector #3 R351 Injector #3
116 116
B48 YL310
71 Y353
B48 YL310
71 Y353
120 120

G320 G320
60 60
Injector #4 Injector #4
Suction air temperature G354 Suction air temperature G354
sensor 117 sensor 117
B6 G321 L311
72
B6 G321 L311
72
B770 B770
1 1
B771 B771
3 3
B772 B772
4 4
BG670 BG670
43 43
BG671 BG671
62 62
BG672 BG672
81 81
RE03003-004 RE03003-004

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-51 4020-51
4) ECM (Engine Control Module) (CX290B) 4) ECM (Engine Control Module) (CX290B)

KEY S/W K2 ECM KEY S/W K2 ECM


S1 LgR530 LR336 24 L374 S1 LgR530 LR336 24 L374
ST M 98
G375
ST M 98
G375
Glow relay A2 W373 CMP sensor B50 Glow relay A2 W373 CMP sensor B50
BrR339 BL687 BrR339 BL687
R2 10 100 R2 10 100
R11 R11
GrR009 GrR010 GrR337 46 GrR009 GrR010 GrR337 46
87 W307 87 W307
Common rail Common rail
82 L317
pressure sensor B52 82 L317
pressure sensor B52
L318 L318
Main relay 90 Main relay 90
WR332 WR332
K33 R1 21
101
G327 K33 R1 21
101
G327
WR333 40 WR333 40
94 GB363 U 94 GB363 U
GW364 EGR position sensor B53 GW364 EGR position sensor B53
F4 R1 93 V F4 R1 93 V
RG125 WR330 GR365 RG125 WR330 GR365
2 92 W 2 92 W
WR331 5 WR331 5

Engine stop S / W 111 WR360 U Engine stop S / W 111 WR360 U


S9 RG126 LG340
47 103 WB361 V M EGR valve motor M15 S9 RG126 LG340
47 103 WB361 V M EGR valve motor M15
110 WL362 110 WL362
W W

WB303 WB303
DIAGNOSTIC Connector 80 DIAGNOSTIC Connector 80
CN51 67
Y313
Oil pressure sensor B21 CN51 67
Y313
Oil pressure sensor B21
X4 BY323 X4 BY323
DIAG S/W 79 DIAG S/W 79
BG691 PB083 PB082 BG691 PB083 PB082
52 RG316 BY 52 RG316 BY
84 Coolant temperature sensor B1 84 Coolant temperature sensor B1
MEMORY CLEAR YG315 BY MEMORY CLEAR YG315 BY
X23 BG692 BrY084
32
83 Fuel temperature sensor B3 X23 BG692 BrY084
32
83 Fuel temperature sensor B3
RW304 RW304
95 95

91 L314 Boost 91 L314 Boost


pressure sensor B47 pressure sensor B47
GW324 GW324
109 109
GR312 RL GR312 RL
74 Boost temperature sensor B51 74 Boost temperature sensor B51
Computer A R370 Computer A R370
G372 G372
L371 CKP sensor B49 L371 CKP sensor B49
107 107
A1 CNC2-6
P040 P042
18 108
BW689 A1 CNC2-6
P040 P042
18 108
BW689

PG041 PG043 RW368 PG041 PG043 RW368


CNC2-14 37 105 CNC2-14 37 105
113 RW369 SCV (suction control valve) Y35 113 RW369 SCV (suction control valve) Y35
89 RG366 89 RG366
RG367 RG367
97 97

121 W350 Injector #1 121 W350 Injector #1


L352 L352
119 119

Injector #2 Injector #2
WB356 WB356
114 114

Injector #3 Injector #3
BARO 117
G354 BARO 117
G354
(atmospheric pressure) (atmospheric pressure)
sensor R351 Injector #4 sensor R351 Injector #4
W300 116 W300 116
61 61
B48 YL310 115
WR357 B48 YL310 115
WR357
71 71
Injector #5 Injector #5
G320 G320
60 Y353 60 Y353
120 120
G321 L311 G321 L311
72 72
Injector #6 Injector #6
B6 Suction air temperature P355
B6 Suction air temperature P355
sensor 118 sensor 118
B770 B770
1 1
B771 B771
3 3
B772 B772
4 4
BG670 BG670
43 43
BG671 BG671
62 62
BG672 BG672
81 81
BE03002-004 BE03002-004

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-52 4020-52
5) Monitor Display 5) Monitor Display

M4 M4
A4 Wiper controller A4 Wiper controller
Washer Washer
F14 BrR190 2
WV841
M
B742 F14 BrR190 2
WV841
M
B742
1 1
Wiper motor Wiper motor
GrR GrR
13 VW 13 VW
YR 7 YR 7
12
8
VR M M3 12
8
VR M M3
LR 11 LR 11
GW GW
5 5
GR GR
6 6

P1 Monitor Display S14 P1 Monitor Display S14


Breaker / crusher switch Breaker / crusher switch
19 WIPER INT OUT1 19 WIPER INT OUT1
GW Crusher GW Crusher
18 WIPER CNT OUT2 IN3 CRUSH S / W 17 BG 18 WIPER CNT OUT2 IN3 CRUSH S / W 17 BG
LW LW
IN2 BREAKER S / W 16 IN2 BREAKER S / W 16
3 WASHER OUT3 Breaker 3 WASHER OUT3 Breaker
S35 OPT 2nd speed S35 OPT 2nd speed
S/W
BG
S/W
BG
Y Y
Computer A IN4 OPT 2ND SPEED 15 Computer A IN4 OPT 2ND SPEED 15

CNC2-4
PW055
13 MON TXD UART S54 Front window L / S CNC2-4
PW055
13 MON TXD UART S54 Front window L / S
A1 A1
PL056 YG BG PL056 YG BG
CNC2-12 4 MON RXD UART IN1 FRONT WINDOW 6 CNC2-12 4 MON RXD UART IN1 FRONT WINDOW 6
VG VG

F5 W130 W135
F5 W130 W135
1 BATT BG 1 BATT BG
GND 20 GND 20
F7 R155 Alternator F7 R155 Alternator
2 IGN 2 IGN
BrW525 BrW525
HOUR 7 L HOUR 7 L
G2 G2

CLOCK CLOCK
G G
P9 8 14 ILUMI P9 8 14 ILUMI
Cab light 70 W Cab light 70 W

K11 E3 K11 E3
Cab light 70 W Cab light 70 W
R4 R4
GR903 GR903
F26 GrR185
F26 GrR185
WR824 WR824
R4 Boom light 70 W R4 Boom light 70 W
F16 Y900 B740 F16 Y900 B740
LW180 WR823 WR 9 LAMP OUT4
E2 LW180 WR823 WR 9 LAMP OUT4
E2
R3 R3
House light 70 W House light 70 W
R3 L901 B741 R3 L901 B741
Y900 Y900
K10 K10
F15 LgW175 F15 LgW175
R6
LY830
8 HORN VOL OUT5 E1 R6
LY830
8 HORN VOL OUT5 E1
S15 Horn S / W S15 Horn S / W
G851 G B722 G851 G B722
K39 R5 K39 R5
(L) (L)
R5 LR907 B747 R5 LR907 B747
H H
K38 (R) K38 (R)
R6 YR909 B749 R6 YR909 B749
H H
K39 H1 K39 H1
RE03003-005 RE03003-005

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-53 4020-53
6) Air Conditioner 6) Air Conditioner

K6 S52 Y8 K6 S52 Y8
Dust S / W Magnetic clutch Dust S / W Magnetic clutch
R12 R12
BrR GW980 W981 B BrR GW980 W981 B

B720 B720
F12 F12
LR205 R BrW556 BrW556 LR205 R BrW556 BrW556
R12 CN29-18 R12 CN29-18
B721
CN28-6 A9 B721
CN28-6 A9
A6 Filter check A6 Filter check
K17 M8 W557 K17 M8 W557
Blower amp CN29-21 Blower amp CN29-21
Blower motor WG558 Blower motor WG558
F11 R13 CN29-22 F11 R13 CN29-22
WR200 LR RL BrY551 WR200 LR RL BrY551
M CN29-13 M CN29-13
LB550 CN29-12 LB550 CN29-12
F10 F10
VR547 VW548 VR547 VW548
R13 CN29-8 R13 CN29-8
VR195 VR195
CN28-14 CN28-14
Evaporator sensor Evaporator sensor
L560 L560
B6 CN28-2 B6 CN28-2

Temperature sensor Temperature sensor


Sb559 Sb559
R4 CN28-1 R4 CN28-1
BG620 BG620
CN28-5 CN28-5
Solar radiation Solar radiation
WY563 WY563
sensor B61 CN28-7 sensor B61 CN28-7
WL564 WL564
CN28-8 CN28-8
GR541 GR541 GR541 GR541
Motor actuator CN29-2 Motor actuator CN29-2
(air mix) M (air mix) M
G555 G555 G555 G555
CN29-17 CN29-17
M7 M7
GW542 GW542 GW542 GW542
CN29-3 CN29-3
LY540 LY540 CN29-1 LY540 LY540 CN29-1
GL553 GL553 CN29-15 GL553 GL553 CN29-15
BL549 BL549 BL549 BL549
CN29-11 CN29-11

Motor actuator LY
Air conditioner Motor actuator LY
Air conditioner
S/W S/W
(mode) YL552 YL552 CN29-14 panel (mode) YL552 YL552 CN29-14 panel
B B
YR543 YR543 YR543 YR543
CN29-4 CN29-4
M6 M Front window M6 M Front window
Y554 Y554 L/S Y554 Y554 L/S
CN29-16 CN29-16
BG615 BG615
CN28-10 CN28-10

YW544 YW544 YW544 YW544


CN29-5 S54 CN29-5 S54
LR545 LR545 LR545 LR545
Motor actuator CN29-6 Motor actuator CN29-6
(recirculate) M (recirculate) M
M5 LG562 LG562 CN28-4 M5 LG562 LG562 CN28-4

S1 S1
LW546 LW546 LW546 LW546
CN29-7 CN29-7
KEY S / W KEY S / W
LgR530 LgR532 LgR530 LgR532
B M CN29-20 B M CN29-20
Computer A Computer A
OL822 OL822
CNC4-19 CN28-11 CNC4-19 CN28-11
K10 A1 K10 A1
R3 Y900 Y904 R3 Y900 Y904
CN28-13 CN28-13

Room lamp Room lamp


OFF
E4 OFF
E4
R9 DOOR VY480 R9 DOOR VY480
LR906 CN28-9 LR906 CN28-9
ON ON
K35 K35

RE03003-006 RE03003-006

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-54 4020-54
7) Lever Lock 7) Lever Lock

Lever lock L / S Lever lock solenoid Lever lock L / S Lever lock solenoid
F25 VW170 OR850 B760
F25 VW170 OR850 B760

S51 Y2 S51 Y2

KEY S / W KEY S / W
S1 BG609 B600 S1 BG609 B600
B M ST R11
B M ST R11

F3 RW120 R11 Safety relay F3 RW120 R11 Safety relay

K34 GrR010 K7 K34 GrR010 K7


S S

BrR523 B750 B700 BrR523 B750 B700


R E R E
Computer A Computer A
BrR523 BrR523
CN1-8 CN1-8
A1 Alternator A1 Alternator

Br016 Br016
L G2 L G2
G015 G015
R R

RE03003-007 RE03003-007

8) Horn 8) Horn

S15 S15
K38 K38
Horn S / W Horn S / W
F15 LgW175 LgW176 G851 G B722 F15 LgW175 LgW176 G851 G B722
R5 R5
Horn Horn
Horn (L) Horn (L)
LgW175 R5 LR907 LR907 B747 LgW175 R5 LR907 LR907 B747
H H1 H H1

LR908
Horn (R) LR908
Horn (R)
R6 YR909 B749 R6 YR909 B749
H H1 H H1

K39 Monitor S / W K39 Monitor S / W

LgW177 LY830 LgW177 LY830


R6 CN5-8 P1 R6 CN5-8 P1

RE03003-008 RE03003-008

Lep SC210B4020-1EN Issued 11-07 Lep SC210B4020-1EN Issued 11-07


4020-55 4020-55
9) Working Light 9) Working Light

Cab light 70 W Cab light 70 W


K11 E3 K11 E3

R4 Cab light 70 W R4 Cab light 70 W


F26 GrR185 GR903
F26 GrR185 GR903
GrR185 GrR185
E3 E3

GrR186 R4 WR824 GrR186 R4 WR824

Monitor S / W Monitor S / W
F16 F16
LW180 LW181 WR823 E1 LW180 LW181 WR823 E1
R3 CN5-9 R3 CN5-9

R3
House light 70 W R3
House light 70 W
LW180 Y900 L901 B741 LW180 Y900 L901 B741
E2 E2
K10 Boom light 70 W K10 Boom light 70 W
Y900 B740 Y900 B740
E1 E1

RE03003-009 RE03003-009

10) Option 10) Option

Y27 Y27
F9 Breaker F9 Breaker
LW260 LW260 LY807 LY807 LW260 LW260 LY807 LY807

B23 VY463 B23 VY463


OPT(2SP) OPT(2SP)
LW261 BrY855 LG856 GL858 LW261 BrY855 LG856 GL858
Y9 Y9
(LB856) (LB856)
S31 S31
OPT1 LEV R-R Knob (R) OPT1 LEV R-R Knob (R)
LW262 GL861 GL861 B714 LW262 GL861 GL861 B714
Y23 Y23

OPT1 LEV R-L


S32 Knob (L) OPT1 LEV R-L
S32 Knob (L)
LW263 GW862 GW862 B713 LW263 GW862 GW862 B713
Y24 Y24

S33 Knob (R) S33 Knob (R)


OPT2 LEV L-R OPT2 LEV L-R
LW264 YL863 YL863 B724 LW264 YL863 YL863 B724
Y25 Y25
YL466

YL466
S34 Knob (L) S34 Knob (L)
OPT2 LEV L-L OPT2 LEV L-L
LW265 YG864 YG864 B723 LW265 YG864 YG864 B723
Y26 Y26
YG467

YG467
GY464 GY464
A1 A1
RE03003-010 RE03003-010

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4020-56 4020-56
11) Others 11) Others

E51 Cigar lighter E51 Cigar lighter


F19 F19
YR210 B YR210 B

YR212 B712 B711 YR212 B712 B711


YR211 YR211 To CAB. SEAT X6 YR211 YR211 To CAB. SEAT X6

M14 Fuel pump M14 Fuel pump


F23 F23
PW230 B753 B700 PW230 B753 B700
M M
PW231 B754 PW231 B754

DC / DC converter DC / DC converter
F20 OR220
U1 F20 OR220
U1
CN22-6 CN22-6

F7 R150 R157
F7 R150 R157
CN22-2 CN22-2

12 V output RY280 12 V output RY280


CN45 CN22-3 CN45 CN22-3

12 V output WR281 12 V output WR281


CN46 CN22-1 CN46 CN22-1
WR282

WR282
B705 B700 B705 B700
CN22-5 CN22-5
Accessory socket 12V X15 Accessory socket 12V X15

BW706 BW706
CN47 CN22-4 CN47 CN22-4

RE03003-011 RE03003-011

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12) Electrical Symbol List 12) Electrical Symbol List

Symbol Name Symbol Name Symbol Name Symbol Name


Fuse Variable solenoid valve Fuse Variable solenoid valve

Diode Resistor Diode Resistor

LED Variable resistor LED Variable resistor

Toggle switch "a" contact Variable resistor Toggle switch "a" contact Variable resistor

Push switch "a" contact Alarm Push switch "a" contact Alarm

A A
Limit switch "a" contact Buzzer Limit switch "a" contact Buzzer

B B
Limit switch "b" contact Horn Limit switch "b" contact Horn

H H
Relay coil Motor Relay coil Motor
R M R M
Relay contact "a" contact Solar radiation sensor Relay contact "a" contact Solar radiation sensor
R R

Relay contact "b" contact Speaker Relay contact "b" contact Speaker
R R

Solenoid valve Lamp Solenoid valve Lamp

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This page is left blank intentionally This page is left blank intentionally

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4021

4021
Section Section
4021 4021

ENGINE ERROR CODE (DTC) ENGINE ERROR CODE (DTC)

Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B4021-0EN October 2008 CNH Lep SM130B4021-0EN October 2008
4021-2 4021-2
TABLE OF CONTENTS TABLE OF CONTENTS
Special tools............................................................................................................................................................. 4 Special tools............................................................................................................................................................. 4
On-board check procedure for sensors.................................................................................................................... 5 On-board check procedure for sensors.................................................................................................................... 5
DTC: 0087 DTC: 0087
Abnormally Low Common Rail Pressure (supply pump not sending pressure)................................................... 6 Abnormally Low Common Rail Pressure (supply pump not sending pressure)................................................... 6
DTC: 0088 DTC: 0088
Abnormally High Common Rail Pressure (1st stage or 2nd stage) ................................................................... 11 Abnormally High Common Rail Pressure (1st stage or 2nd stage) ................................................................... 11
DTC: 0089 DTC: 0089
Common Rail Pressure Abnormality (supply pump sending too much pressure).............................................. 15 Common Rail Pressure Abnormality (supply pump sending too much pressure).............................................. 15
DTC: 0090 DTC: 0090
SCV (suction control valve) Drive System Disconnection, +B Short, or GND Short.......................................... 18 SCV (suction control valve) Drive System Disconnection, +B Short, or GND Short.......................................... 18
DTC: 0107 DTC: 0107
Atmospheric Pressure Sensor Circuit Abnormality (abnormally low voltage) .................................................... 22 Atmospheric Pressure Sensor Circuit Abnormality (abnormally low voltage) .................................................... 22
DTC: 0108 DTC: 0108
Atmospheric Pressure Sensor Circuit Abnormality (abnormally high voltage)................................................... 27 Atmospheric Pressure Sensor Circuit Abnormality (abnormally high voltage)................................................... 27
DTC: 0112 DTC: 0112
IAT (suction air temperature) Sensor Abnormality (abnormally low voltage)..................................................... 32 IAT (suction air temperature) Sensor Abnormality (abnormally low voltage)..................................................... 32
DTC: 0113 DTC: 0113
IAT (suction air temperature) Sensor Abnormality (abnormally high voltage) ................................................... 37 IAT (suction air temperature) Sensor Abnormality (abnormally high voltage) ................................................... 37
DTC: 0117 DTC: 0117
ECT (engine coolant temperature) Sensor Abnormality (abnormally low voltage) ............................................ 42 ECT (engine coolant temperature) Sensor Abnormality (abnormally low voltage) ............................................ 42
DTC: 0118 DTC: 0118
ECT (engine coolant temperature) Sensor Abnormality (abnormally high voltage)........................................... 47 ECT (engine coolant temperature) Sensor Abnormality (abnormally high voltage)........................................... 47
DTC: 0182 DTC: 0182
FT (fuel temperature) Sensor Abnormality (abnormally low voltage)................................................................. 53 FT (fuel temperature) Sensor Abnormality (abnormally low voltage)................................................................. 53
DTC: 0183 DTC: 0183
FT (fuel temperature) Sensor Abnormality (abnormally high voltage) ............................................................... 58 FT (fuel temperature) Sensor Abnormality (abnormally high voltage) ............................................................... 58
DTC: 0192 DTC: 0192
Common Rail Pressure Sensor Abnormality (abnormally low voltage) ............................................................. 63 Common Rail Pressure Sensor Abnormality (abnormally low voltage) ............................................................. 63
DTC: 0193 DTC: 0193
Common Rail Pressure Sensor Abnormality (abnormally high voltage) ............................................................ 68 Common Rail Pressure Sensor Abnormality (abnormally high voltage) ............................................................ 68
DTC: 0201 DTC: 0201
No. 1 Cylinder Injector Drive System Disconnection ......................................................................................... 73 No. 1 Cylinder Injector Drive System Disconnection ......................................................................................... 73
DTC: 0202 DTC: 0202
No. 2 Cylinder Injector Drive System Disconnection ......................................................................................... 78 No. 2 Cylinder Injector Drive System Disconnection ......................................................................................... 78
DTC: 0203 DTC: 0203
No. 3 Cylinder Injector Drive System Disconnection ......................................................................................... 83 No. 3 Cylinder Injector Drive System Disconnection ......................................................................................... 83
DTC: 0204 DTC: 0204
No. 4 Cylinder Injector Drive System Disconnection ......................................................................................... 88 No. 4 Cylinder Injector Drive System Disconnection ......................................................................................... 88
DTC: 0219 DTC: 0219
Overrun .............................................................................................................................................................. 93 Overrun .............................................................................................................................................................. 93
DTC: 0237 DTC: 0237
Boost Pressure Sensor Abnormality (abnormally low voltage) .......................................................................... 95 Boost Pressure Sensor Abnormality (abnormally low voltage) .......................................................................... 95
DTC: 0238 DTC: 0238
Boost Pressure Sensor Abnormality (abnormally high voltage)......................................................................... 99 Boost Pressure Sensor Abnormality (abnormally high voltage)......................................................................... 99
DTC: 0335 DTC: 0335
CKP (crank position) Sensor Abnormality (no signal)...................................................................................... 102 CKP (crank position) Sensor Abnormality (no signal)...................................................................................... 102
DTC: 0336 DTC: 0336
CKP (crank position) Sensor Abnormality (signal abnormality) ....................................................................... 106 CKP (crank position) Sensor Abnormality (signal abnormality) ....................................................................... 106
DTC: 0340 DTC: 0340
CMP (cam position) Sensor Abnormality (no signal) ....................................................................................... 110 CMP (cam position) Sensor Abnormality (no signal) ....................................................................................... 110
DTC: 0341 DTC: 0341
CMP (cam position) Sensor Abnormality (signal abnormality)......................................................................... 115 CMP (cam position) Sensor Abnormality (signal abnormality)......................................................................... 115
DTC: 0380 DTC: 0380
Glow Relay Circuit Abnormality ....................................................................................................................... 119 Glow Relay Circuit Abnormality ....................................................................................................................... 119
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DTC: 0487 DTC: 0487
EGR Position Sensor Abnormality ................................................................................................................... 124 EGR Position Sensor Abnormality ................................................................................................................... 124
DTC: 0488 DTC: 0488
EGR Valve Control Abnormality....................................................................................................................... 128 EGR Valve Control Abnormality....................................................................................................................... 128
DTC: 0522 DTC: 0522
Engine Oil Pressure Sensor Abnormality (abnormally low voltage)................................................................. 132 Engine Oil Pressure Sensor Abnormality (abnormally low voltage)................................................................. 132
DTC: 0523 DTC: 0523
Engine Oil Pressure Sensor Abnormality (abnormally high voltage) ............................................................... 136 Engine Oil Pressure Sensor Abnormality (abnormally high voltage) ............................................................... 136
DTC: 0601 DTC: 0601
ROM Abnormality ............................................................................................................................................ 141 ROM Abnormality ............................................................................................................................................ 141
DTC: 0603 DTC: 0603
EEPROM Abnormality ..................................................................................................................................... 142 EEPROM Abnormality ..................................................................................................................................... 142
DTC: 0606 DTC: 0606
CPU Abnormality ............................................................................................................................................. 143 CPU Abnormality ............................................................................................................................................. 143
DTC: 0611 DTC: 0611
Charge Circuit Abnormality (bank 1)................................................................................................................ 144 Charge Circuit Abnormality (bank 1)................................................................................................................ 144
DTC: 0612 DTC: 0612
Charge Circuit Abnormality (bank 2)................................................................................................................ 147 Charge Circuit Abnormality (bank 2)................................................................................................................ 147
DTC: 1093 DTC: 1093
No Pump Pressure Send ................................................................................................................................. 150 No Pump Pressure Send ................................................................................................................................. 150
DTC: 1095 DTC: 1095
Pressure Limiter Open ..................................................................................................................................... 155 Pressure Limiter Open ..................................................................................................................................... 155
DTC: 1112 DTC: 1112
Boost Temperature Sensor Abnormality (abnormally low voltage).................................................................. 161 Boost Temperature Sensor Abnormality (abnormally low voltage).................................................................. 161
DTC: 1113 DTC: 1113
Boost Temperature Sensor Abnormality (abnormally high voltage) ................................................................ 166 Boost Temperature Sensor Abnormality (abnormally high voltage) ................................................................ 166
DTC: 1173 DTC: 1173
Overheat .......................................................................................................................................................... 170 Overheat .......................................................................................................................................................... 170
DTC: 1261 DTC: 1261
Injector Common 1 Drive System Abnormality ................................................................................................ 174 Injector Common 1 Drive System Abnormality ................................................................................................ 174
DTC: 1262 DTC: 1262
Injector Common 2 Drive System Abnormality ................................................................................................ 180 Injector Common 2 Drive System Abnormality ................................................................................................ 180
DTC: 1345 DTC: 1345
CMP (cam position) Sensor Out of Phase ....................................................................................................... 186 CMP (cam position) Sensor Out of Phase ....................................................................................................... 186
DTC: 1625 DTC: 1625
Main Relay System Abnormality ...................................................................................................................... 188 Main Relay System Abnormality ...................................................................................................................... 188
DTC: 1630 DTC: 1630
A/D Conversion Abnormality............................................................................................................................ 193 A/D Conversion Abnormality............................................................................................................................ 193
DTC: 1632 DTC: 1632
5 V Power Supply 2 Voltage Abnormality (atmospheric pressure sensor power supply) ................................ 194 5 V Power Supply 2 Voltage Abnormality (atmospheric pressure sensor power supply) ................................ 194
DTC: 1633 DTC: 1633
5 V Power Supply 3 Voltage Abnormality (engine oil pressure power supply) ................................................ 197 5 V Power Supply 3 Voltage Abnormality (engine oil pressure power supply) ................................................ 197
DTC: 1634 DTC: 1634
5 V Power Supply 4 Voltage Abnormality (boost pressure sensor power supply) ........................................... 200 5 V Power Supply 4 Voltage Abnormality (boost pressure sensor power supply) ........................................... 200
DTC: 1635 DTC: 1635
5 V Power Supply 5 Voltage Abnormality 5 V Power Supply 5 Voltage Abnormality
(common rail pressure sensor, EGR position sensor power supply) ............................................................... 203 (common rail pressure sensor, EGR position sensor power supply) ............................................................... 203
DTC: 2104 DTC: 2104
CAN Bus Abnormality ...................................................................................................................................... 206 CAN Bus Abnormality ...................................................................................................................................... 206
DTC: 2106 DTC: 2106
CAN Time-out Abnormality .............................................................................................................................. 210 CAN Time-out Abnormality .............................................................................................................................. 210

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SPECIAL TOOLS SPECIAL TOOLS

CNH-EST DIAGNOSTIC TOOL (SCAN TOOL) CNH-EST DIAGNOSTIC TOOL (SCAN TOOL)

The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the operating parameters of elec- The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the operating parameters of elec-
tronic control components (control units, sensors etc.). It is also capable of reading fault codes. tronic control components (control units, sensors etc.). It is also capable of reading fault codes.
To use this tool, please refer to the book provided during the CXB series training sessions. To use this tool, please refer to the book provided during the CXB series training sessions.

BREAKER BOX AND DMM BREAKER BOX AND DMM

Name Name
1. Breaker box 1. Breaker box
2. DMM 2. DMM

Breaker-Box Breaker-Box

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4021-5 4021-5
ON-BOARD CHECK PROCEDURE FOR SENSORS ON-BOARD CHECK PROCEDURE FOR SENSORS

Name Name
1. Coupling connector between engine - the machine 1. Coupling connector between engine - the machine
2. Machine harness 2. Machine harness
3. Sensor connector 3. Sensor connector
4. Engine harness 4. Engine harness

Board-Sensor Board-Sensor

A. Disconnect the coupling connector, and check the sensor from engine harness connector. A. Disconnect the coupling connector, and check the sensor from engine harness connector.
B. Disconnect the connector from sensor, and short the wiring of sensor connector. B. Disconnect the connector from sensor, and short the wiring of sensor connector.
C. Check the harness from coupling connector for open circuit. C. Check the harness from coupling connector for open circuit.
• If both steps 1 and 2 are faulty, repair the harness. • If both steps 1 and 2 are faulty, repair the harness.
Check from step 1 again. Check from step 1 again.
• If only step 1 is faulty, replace the sensor. • If only step 1 is faulty, replace the sensor.

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4021-6 4021-6
DTC: 0087 DTC: 0087
Abnormally Low Common Rail Pressure (supply pump not sending pressure) Abnormally Low Common Rail Pressure (supply pump not sending pressure)

Large amount of engine vibration, unstable idling speed Large amount of engine vibration, unstable idling speed
Output reduction, black smoke produced, and excess output Output reduction, black smoke produced, and excess output
are possible. are possible.

Step 1 Step 1
Perform an actual machine diagnosis service support check. Perform an actual machine diagnosis service support check.

No Go to “Service support No Go to “Service support


Is the action complete? Is the action complete?
Step 2 check”. Step 2 check”.
Inspect the fuel system. Inspect the fuel system.
Yes Yes
1. In the high-pressure and low-pressure lines, inspect for looseness 1. In the high-pressure and low-pressure lines, inspect for looseness
in connections (fuel leaking), crushing, and clogging. in connections (fuel leaking), crushing, and clogging.
2. Inspect for any freezing or waxing in the fuel line, fuel filter and fuel 2. Inspect for any freezing or waxing in the fuel line, fuel filter and fuel
tank. tank.
3. Inspect whether foreign matter is clogged in the feed pipe inside 3. Inspect whether foreign matter is clogged in the feed pipe inside
the fuel tank. No the fuel tank. No
Is the fuel system normal? Is the fuel system normal?

Yes Yes

Step 3 Step 3
Perform repair or replacement for any locations where problems are Perform repair or replacement for any locations where problems are
found. found.

Is the action complete? Is the action complete?

Yes Go to step 18. Yes Go to step 18.

Step 4 Step 4
Check on the oil level gauge whether the oil level has risen, and check Check on the oil level gauge whether the oil level has risen, and check
for diesel odors. for diesel odors.

No No
Was a problem detected? Was a problem detected?
Step 5 Step 5
Inspect the fuel pipe connections of each injector, and replace any Inspect the fuel pipe connections of each injector, and replace any
injectors for which fuel leaks are confirmed. injectors for which fuel leaks are confirmed.
Note: Note:
See the “Engine” section in the Service Manual for the work See the “Engine” section in the Service Manual for the work
procedures. Is the action complete? procedures. Is the action complete?

Yes Go to step 18. Yes Go to step 18.

Step 7 Step 7
Inspect the injector. Inspect the injector.
1. Delete the diagnostic trouble code. Step 6 No 1. Delete the diagnostic trouble code. Step 6 No
(See the service support DIAG (trouble diagnosis) screen for Go to step 20. (See the service support DIAG (trouble diagnosis) screen for Go to step 20.
Do you have a scan tool (KW communication)? Do you have a scan tool (KW communication)?
information on deleting diagnostic trouble codes.) information on deleting diagnostic trouble codes.)
2. Start the engine. 2. Start the engine.
3. Select “Actuator test” from the menu. 3. Select “Actuator test” from the menu.
4. Select “Injection stop at each injector” in “Common rail system”. 4. Select “Injection stop at each injector” in “Common rail system”.
5. Press the “OFF” soft key to stop the injection of the injectors for No 5. Press the “OFF” soft key to stop the injection of the injectors for No
Was there a cylinder in which engine vibration Was there a cylinder in which engine vibration
each cylinder one by one, and check the change in the engine each cylinder one by one, and check the change in the engine
and engine noise did not change? and engine noise did not change?
noise. noise.

Yes Go to step 9. Yes Go to step 9.

Step 8 Step 8
Replace the injectors of the cylinders for which Replace the injectors of the cylinders for which
the engine noise did not change. the engine noise did not change.
Note: Note:
See the “Engine” section in the Service Manual Is the action complete? See the “Engine” section in the Service Manual Is the action complete?
for the work procedures. for the work procedures.

Yes Yes
Go to step 18. Go to step 18.

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4021-7 4021-7

From step 7 From step 7

Step 9 Step 9
Inspect the common rail pressure. Inspect the common rail pressure.
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Use the scan tool to check the “Common rail pressure” display in Reference value 2. Use the scan tool to check the “Common rail pressure” display in Reference value
the data display. When engine is stopped: Difference - 30 MPa the data display. When engine is stopped: Difference - 30 MPa
3. Start and idle the engine. During idling, revving: ± 5 MPa 3. Start and idle the engine. During idling, revving: ± 5 MPa
4. Use the scan tool to check the “Differential fuel rail pressure” No 4. Use the scan tool to check the “Differential fuel rail pressure” No
display in the data display. Is the “Differential fuel pressure” display in the data display. Is the “Differential fuel pressure”
5. Quickly rev the engine about 5 times. value close to the reference value? 5. Quickly rev the engine about 5 times. value close to the reference value?
6. Use the scan tool to check the “Differential fuel rail pressure” 6. Use the scan tool to check the “Differential fuel rail pressure”
display in the data display. Yes display in the data display. Yes
Go to step 16. Go to step 16.

Step 10 Step 10
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the common rail pressure sensor connector. 2. Remove the common rail pressure sensor connector.
3. Turn the key switch “ON”. No Reference value 3. Turn the key switch “ON”. No Reference value
4. Use the scan tool to check the "Common rail pressure sensor" 4.8 V 4. Use the scan tool to check the "Common rail pressure sensor" 4.8 V
display in the data display. Is the “Common rail pressure sensor” display in the data display. Is the “Common rail pressure sensor”
value at or above the reference value? value at or above the reference value?

Yes Yes

Step 11 Step 11
1. Use the breaker box or DMM to inspect whether there is a short 1. Use the breaker box or DMM to inspect whether there is a short
circuit with another sensor's signal circuit in the signal circuit circuit with another sensor's signal circuit in the signal circuit
between the common rail pressure sensor and ECM. between the common rail pressure sensor and ECM.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 18. Go to step 18.

Step 13 Step 13
1. Check the ECM software version. 1. Check the ECM software version.
2. If the ECM software needs to be updated, perform the rewriting. 2. If the ECM software needs to be updated, perform the rewriting.
For details on checking the ECM and the rewriting, see “How to No Step 12 For details on checking the ECM and the rewriting, see “How to No Step 12
Use EMPS”. Is there an EMPS? Use EMPS”. Is there an EMPS?
Note: Note:
When ECM replacement or rewriting is performed, perform EGR Yes When ECM replacement or rewriting is performed, perform EGR Yes
learning. learning.
[EGR learning method] [EGR learning method]
3. Turn the key switch “ON”. 3. Turn the key switch “ON”.
4. Turn the key switch “OFF”. 4. Turn the key switch “OFF”.
5. Wait about 10 sec. 5. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 14 Step 14
Replace the ECM. Yes Replace the ECM. Yes
Note: Go to step 1. Note: Go to step 1.
When ECM replacement or rewriting is performed, perform EGR When ECM replacement or rewriting is performed, perform EGR
learning. learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
No No
Is the action complete? Is the action complete?

Yes Yes
Go to step 16. Go to step 16.

Step 15 Step 15
Replace the common rail (common rail pressure sensor). Replace the common rail (common rail pressure sensor).

Is the action complete? Is the action complete?

Yes Yes
Go to step 18. Go to step 18.

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4021-8 4021-8

From step 14 From step 14

Step 16 Step 16
1. Delete the diagnostic trouble code. (See the service support DIAG 1. Delete the diagnostic trouble code. (See the service support DIAG
(trouble diagnosis) screen for information on deleting diagnostic (trouble diagnosis) screen for information on deleting diagnostic
trouble codes.) trouble codes.)
2. Start the engine. Reference value 2. Start the engine. Reference value
3. Select “Actuator test” from the menu. ± 5 MPa 3. Select “Actuator test” from the menu. ± 5 MPa
4. Select “Rail pressure control” in “Common rail system”. No 4. Select “Rail pressure control” in “Common rail system”. No
5. Press the “UP” soft key and check the “Differential fuel rail Is the “Differential fuel rail pressure” 5. Press the “UP” soft key and check the “Differential fuel rail Is the “Differential fuel rail pressure”
pressure” value. value withing the reference value range? pressure” value. value withing the reference value range?

Yes Yes

Step 17 Step 17
Replace the supply pump. Replace the supply pump.

Is the action complete? Is the action complete?


Step 18 Step 18
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
Yes Yes
2. Delete the diagnostic trouble code. (See the service support DIAG 2. Delete the diagnostic trouble code. (See the service support DIAG
(trouble diagnosis) screen for information on deleting diagnostic (trouble diagnosis) screen for information on deleting diagnostic
trouble codes.) trouble codes.)
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when diagnostic 4. Perform a test drive under the “Preconditions when diagnostic
trouble code is set”. trouble code is set”.
5. Confirm the diagnostic trouble code. No Has a diagnostic trouble code: 0087 been 5. Confirm the diagnostic trouble code. No Has a diagnostic trouble code: 0087 been
detected? detected?

Yes Go to step 2 Yes Go to step 2

Step 19 Step 19
Check that no diagnostic trouble codes have been detected. Check that no diagnostic trouble codes have been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Step 20 Step 20
Use the injector checker to stop the injection of the injectors and check Use the injector checker to stop the injection of the injectors and check
the change in the engine noise. the change in the engine noise.

No Was there a cylinder in which engine vibration No Was there a cylinder in which engine vibration
and engine noise did not change? and engine noise did not change?

Yes Yes
Step 21 Step 21
Replace the injectors of the cylinders for which the engine noise did Replace the injectors of the cylinders for which the engine noise did
not change. not change.
Note: Note:
See the “Engine” section in the Service Manual for the work See the “Engine” section in the Service Manual for the work
procedures. procedures.

Is the action complete? Is the action complete?

Yes Yes

Step 22 Step 22
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the common rail pressure sensor connector. 2. Remove the common rail pressure sensor connector.
3. Measure the voltage between the ground and the power supply 3. Measure the voltage between the ground and the power supply
terminal of the common rail pressure sensor. No Reference value terminal of the common rail pressure sensor. No Reference value
4.8 V 4.8 V
Is the DMM display at or above the reference Is the DMM display at or above the reference
value? value?

Yes Yes
Go to step 24. Go to step 24.

Go to step 24. Go to step 24.

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4021-9 4021-9

From step 22 From step 22

Step 23 Step 23
1. Use the breaker box or DMM to inspect whether there is a short 1. Use the breaker box or DMM to inspect whether there is a short
circuit with another sensor's signal circuit in the signal circuit circuit with another sensor's signal circuit in the signal circuit
between the common rail pressure sensor and ECM. No Was a problem detected? between the common rail pressure sensor and ECM. No Was a problem detected?
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Yes Yes
Go to step 18. Go to step 18.

Go to step 12. Go to step 12.

From step 22 From step 22

Step 24 Step 24
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
(See the service support DIAG (trouble diagnosis) screen for No (See the service support DIAG (trouble diagnosis) screen for No
information on deleting diagnostic trouble codes.) Has a diagnostic trouble code: 0087 been information on deleting diagnostic trouble codes.) Has a diagnostic trouble code: 0087 been
3. Turn the key switch "OFF" for at least 10 sec. detected? 3. Turn the key switch "OFF" for at least 10 sec. detected?
4. Perform a test drive under the "Preconditions when diagnostic 4. Perform a test drive under the "Preconditions when diagnostic
trouble code is set". trouble code is set".
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 18. Go to step 18.

Go to step 12. Go to step 12.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-10 4021-10
Block diagram Block diagram
EGR MOTOR EGR MOTOR

EGR POSITION SENSOR EGR POSITION SENSOR

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• At least 900 min-1 • At least 900 min-1
Diagnostic aid Diagnostic aid
Possible causes include the following. Possible causes include the following.
• Injector internal trouble • Injector internal trouble
• Supply pump internal trouble • Supply pump internal trouble
• Fuel system line abnormality (fuel leaking, clogging, or crushing) • Fuel system line abnormality (fuel leaking, clogging, or crushing)
• Fuel filter abnormality (clogging) • Fuel filter abnormality (clogging)
• Fuel tank abnormality (clogging) • Fuel tank abnormality (clogging)
• Pressure limiter trouble (operation below regulated pressure, sealant deterioration) • Pressure limiter trouble (operation below regulated pressure, sealant deterioration)
• ECM trouble • ECM trouble
• Common rail pressure sensor trouble • Common rail pressure sensor trouble

Breaker box inspection procedure Breaker box inspection procedure


For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with other 82-GND 1 V or Short circuit with other 82-GND 1 V or
11, 23 value mea- connector. 0V 11, 23 value mea- connector. 0V
signal circuit 90-GND higher signal circuit 90-GND higher
surement • Key switch “ON” surement • Key switch “ON”

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-11 4021-11
DTC: 0088 DTC: 0088
Abnormally High Common Rail Pressure (1st stage or 2nd stage) Abnormally High Common Rail Pressure (1st stage or 2nd stage)

Large amount of engine vibration, idle speed problem Large amount of engine vibration, idle speed problem

Output reduction, rev-up defect Output reduction, rev-up defect

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

Step 2 Step 2
1. Start the engine. No 1. Start the engine. No
Go to “Service Go to “Service
2. Confirm the diagnostic trouble code. Is the action complete? 2. Confirm the diagnostic trouble code. Is the action complete?
support check”. support check”.
3. Immediately after replacing fuel related parts? 3. Immediately after replacing fuel related parts?
There is a high possibility that the air bleeding There is a high possibility that the air bleeding
during the replacement of fuel related parts was during the replacement of fuel related parts was
ineffective. Perform the air bleeding again. Check ineffective. Perform the air bleeding again. Check
Yes Yes
the diagnostic trouble code after performing the air the diagnostic trouble code after performing the air
bleeding. bleeding.

No Has a diagnostic trouble code: No Has a diagnostic trouble code:


0088, 0192, 0193, or 1635 been 0088, 0192, 0193, or 1635 been
detected? detected?

Yes Go to the detected Yes Go to the detected


diagnostic trouble diagnostic trouble
code. code.

No Step 3 No Step 3
Step 4 Do you have a scan tool (KW Step 4 Do you have a scan tool (KW
1. Turn the key switch “OFF” for 30 sec. or longer. communication)? 1. Turn the key switch “OFF” for 30 sec. or longer. communication)?
2. Start the engine. 2. Start the engine.
3. Use the scan tool to check the “Differential fuel rail Yes 3. Use the scan tool to check the “Differential fuel rail Yes
pressure” display in the data display. pressure” display in the data display.

Reference value Reference value


Pressure difference ± 5 MPa Pressure difference ± 5 MPa
(During idling) (During idling)
Go to diagnostic aid. Go to diagnostic aid.
Is the “Differential fuel rail Is the “Differential fuel rail
Step 5 Step 5
pressure” value within the pressure” value within the
1. Inspect the fuel return line between the supply 1. Inspect the fuel return line between the supply
reference value range? reference value range?
pump and the fuel tank for any damage or twisting. pump and the fuel tank for any damage or twisting.
2. Inspect the bent hose of the fuel tank to check for 2. Inspect the bent hose of the fuel tank to check for
Yes Yes
any clogging or twisting. any clogging or twisting.
3. Inspect the inside of the fuel tank to check for any 3. Inspect the inside of the fuel tank to check for any
foreign matter. foreign matter.
4. Repair as necessary if a problem is detected. 4. Repair as necessary if a problem is detected.

No No
Is the action complete? Is the action complete?

Step 6 Step 6
1. An abnormal value may have been detected for the Yes 1. An abnormal value may have been detected for the Yes
common rail pressure sensor. Replace the common common rail pressure sensor. Replace the common
rail (common rail pressure sensor). rail (common rail pressure sensor).
Note: Note:
See the “Engine” section in the Service Manual for the See the “Engine” section in the Service Manual for the
work procedures. work procedures.
2. Confirm the diagnostic trouble code. 2. Confirm the diagnostic trouble code.
No No
Was a problem detected? Was a problem detected?

Step Yes Step Yes


Replace the supply pump. Replace the supply pump.
Note: Note:
See the “Engine” section in the Service Manual for the See the “Engine” section in the Service Manual for the
work procedures. Is the action complete? work procedures. Is the action complete?

Yes Yes

Step Step
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. No 2. Delete the diagnostic trouble code. No
(See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: (See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code:
screen for information on deleting diagnostic trouble 0088 been detected? screen for information on deleting diagnostic trouble 0088 been detected?
codes.) codes.)
3. Turn the key switch “OFF” for at least 10 sec. Yes 3. Turn the key switch “OFF” for at least 10 sec. Yes
4. Perform a test drive under the “Preconditions when 4. Perform a test drive under the “Preconditions when
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Go to step 9. Go to step 9.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-12 4021-12

From step 8. From step 8.

Step 9 Step 9
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

No No
Has any other diagnostic trouble code been detected? Check repair. Has any other diagnostic trouble code been detected? Check repair.

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-13 4021-13
Block diagram Block diagram
EGR MOTOR EGR MOTOR

EGR POSITION SENSOR EGR POSITION SENSOR

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


1st stage 1st stage
• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 0088, 0192, 0193, and 1635 are not detected. • DTC: 0088, 0192, 0193, and 1635 are not detected.
• Actual common rail pressure is at least 2 MPa and engine speed is at least 70 min-1. • Actual common rail pressure is at least 2 MPa and engine speed is at least 70 min-1.
2nd stage 2nd stage
• Battery voltage is normal. • Battery voltage is normal.
• DTC: 0088, 0192, 0193, and 1635 are not detected. • DTC: 0088, 0192, 0193, and 1635 are not detected.
• Actual common rail pressure is at least 2 MPa and engine speed is at least 70 min-1. • Actual common rail pressure is at least 2 MPa and engine speed is at least 70 min-1.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-14 4021-14
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-15 4021-15
DTC: 0089 DTC: 0089
Common Rail Pressure Abnormality (supply pump sending too much pressure) Common Rail Pressure Abnormality (supply pump sending too much pressure)

Large amount of engine vibration, idle speed problem, output reduction Large amount of engine vibration, idle speed problem, output reduction

Rev-up defect Rev-up defect

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Go to “Service No Go to “Service
Is the action complete? Is the action complete?
support check”. support check”.
Step 2 Step 2
1. Start the engine. 1. Start the engine.
2. Confirm the diagnostic trouble code. 2. Confirm the diagnostic trouble code.
Yes Yes

No Has a diagnostic trouble code: No Has a diagnostic trouble code:


0088, 0192, 0193, or 1635 been 0088, 0192, 0193, or 1635 been
detected? detected?

Yes Go to the detected Yes Go to the detected


diagnostic trouble diagnostic trouble
code. code.

Step 3 Step 3
Step 4 Do you have a scan tool (KW Go to step 12. Step 4 Do you have a scan tool (KW Go to step 12.
1. Turn the key switch “OFF” for 30 sec. or longer. communication)? 1. Turn the key switch “OFF” for 30 sec. or longer. communication)?
2. Start the engine. 2. Start the engine.
3. Use the scan tool to check the “Differential fuel rail Yes 3. Use the scan tool to check the “Differential fuel rail Yes
pressure” display in the data display. pressure” display in the data display.

Reference value Reference value


Pressure difference ± 5 MPa Pressure difference ± 5 MPa

No Is the “Differential fuel rail No Is the “Differential fuel rail


pressure” value within the pressure” value within the
Step 5 reference value range? Step 5 reference value range?
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Wait for 2 min. until the pressure in the common rail Yes 2. Wait for 2 min. until the pressure in the common rail Yes
Go to diagnostic Go to diagnostic
drops. drops.
aid. aid.
3. Turn the key switch “ON”. Do not start the engine. 3. Turn the key switch “ON”. Do not start the engine.
4. Use the scan tool to check the “Differential fuel rail 4. Use the scan tool to check the “Differential fuel rail
pressure” display in the data display. pressure” display in the data display.

No Reference value No Reference value


Pressure difference -30 MPa Pressure difference -30 MPa

Step 6 Is the “Differential fuel rail Step 6 Is the “Differential fuel rail
1. Turn the key switch “OFF”. pressure” value close to the 1. Turn the key switch “OFF”. pressure” value close to the
2. Remove the SCV (suction control valve) connector. reference value? 2. Remove the SCV (suction control valve) connector. reference value?
3. Inspect the terminal of the SCV harness connector 3. Inspect the terminal of the SCV harness connector
for any connection problems or intermittent Yes for any connection problems or intermittent Yes
problems. problems.
4. Remove the ECM harness connector. 4. Remove the ECM harness connector.
5. Inspect the terminal of the ECM harness connector 5. Inspect the terminal of the ECM harness connector
for any connection problems or intermittent for any connection problems or intermittent
problems. problems.
6. Repair as necessary if a problem is detected. 6. Repair as necessary if a problem is detected.
No No
Was a problem detected? Go to step 9. Was a problem detected? Go to step 9.

Step 7 Yes Step 7 Yes


1. Turn the key switch “OFF”. Go to step 10. 1. Turn the key switch “OFF”. Go to step 10.
2. Remove the common rail pressure sensor 2. Remove the common rail pressure sensor
connector. connector.
3. Inspect the terminal of the common rail pressure 3. Inspect the terminal of the common rail pressure
sensor harness connector for any connection sensor harness connector for any connection
problems or intermittent problems. problems or intermittent problems.
4. Remove the ECM harness connector. No 4. Remove the ECM harness connector. No
5. Inspect the terminal of the ECM harness connector Was a problem detected? 5. Inspect the terminal of the ECM harness connector Was a problem detected?
for any connection problems or intermittent for any connection problems or intermittent
problems. problems.
6. Repair as necessary if a problem is detected. Yes 6. Repair as necessary if a problem is detected. Yes
Go to step 10. Go to step 10.

Step 8 Step 8
Replace the common rail (common rail pressure Replace the common rail (common rail pressure
sensor). sensor).
Note: Note:
See the “Engine” section in the Service Manual for the Is the action complete? See the “Engine” section in the Service Manual for the Is the action complete?
work procedures. work procedures.

Yes Yes
Go to step 10. Go to step 10.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-16 4021-16

From step 6 From step 6

Step 9 Step 9
Replace the supply pump. Replace the supply pump.
Note: Note:
See the “Engine” section in the Service Manual for the work See the “Engine” section in the Service Manual for the work
procedures. procedures.
Is the action complete? Is the action complete?

Yes Yes

Step 10 Step 10
Recheck the diagnostic trouble code. No Has a diagnostic trouble code: Recheck the diagnostic trouble code. No Has a diagnostic trouble code:
1. Connect all harnesses. 1093 been detected? 1. Connect all harnesses. 1093 been detected?
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
(See the service support DIAG (trouble diagnosis) screen (See the service support DIAG (trouble diagnosis) screen
Yes Yes
for information on deleting diagnostic trouble codes.) Go to step 2. for information on deleting diagnostic trouble codes.) Go to step 2.
3. Turn the key switch “ON” for at least 10 sec. 3. Turn the key switch “ON” for at least 10 sec.
4. Perform a test drive under the “Preconditions when 4. Perform a test drive under the “Preconditions when
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Has any other diagnostic trouble No Has any other diagnostic trouble No
Check repair. Check repair.
Step 11 code been detected? Step 11 code been detected?
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.
Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Step 12 Step 12
1. Check the external appearance for any harness damage 1. Check the external appearance for any harness damage
between the ECM and common rail pressure sensor. between the ECM and common rail pressure sensor.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
No No
Is the action complete? Go to step 6. Is the action complete? Go to step 6.

Yes Yes

Go to step 5. Go to step 5.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-17 4021-17
Block diagram Block diagram
EGR MOTOR EGR MOTOR

EGR POSITION SENSOR EGR POSITION SENSOR

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 0089, 0192, 0193, and 1635 are not detected. • DTC: 0089, 0192, 0193, and 1635 are not detected.
• Engine coolant temperature at least 60C and engine speed at least 375 min-1 • Engine coolant temperature at least 60C and engine speed at least 375 min-1
• The ratio for the fuel flow command signal to the SCV is 40 % or less, or the target pressure send quantity to the SCV is 90 • The ratio for the fuel flow command signal to the SCV is 40 % or less, or the target pressure send quantity to the SCV is 90
mm3/sec. or less. mm3/sec. or less.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.
Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-18 4021-18
DTC: 0090 DTC: 0090
SCV (suction control valve) Drive System Disconnection, +B Short, or GND Short SCV (suction control valve) Drive System Disconnection, +B Short, or GND Short

Due to disconnection or short, stalling and revving are both possible, as well as Due to disconnection or short, stalling and revving are both possible, as well as
black smoke and excess output black smoke and excess output

Step 1 Step 1
Perform an actual machine diagnosis service Perform an actual machine diagnosis service

No No
Is the action complete? Go to “Service support check”. Is the action complete? Go to “Service support check”.

Yes Yes

No Step 2 No Step 2
Step 3 Step 3
1. Connect the scan tool. Do you have a scan tool (KW communication)? 1. Connect the scan tool. Do you have a scan tool (KW communication)?
2. Start the engine. 2. Start the engine.
3. Use the scan tool to check the “SCV F / B” 3. Use the scan tool to check the “SCV F / B”
display. display.
Yes Yes

Reference value Reference value


Step 4 No 50 mA Step 4 No 50 mA
1. Use the breaker box or DMM to check Is the “SCV F / B” value at or below the reference value? 1. Use the breaker box or DMM to check Is the “SCV F / B” value at or below the reference value?
whether the conditions below are present in whether the conditions below are present in
the circuit between the SCV and ECM. Yes the circuit between the SCV and ECM. Yes
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection If there is no breaker box, see the Inspection
procedures for sensors on actual machine. procedures for sensors on actual machine.
• Short circuit with GND • Short circuit with GND
• Disconnection • Disconnection
• High resistance • High resistance
No No
2. Repair or replace as necessary if a problem is Was a problem detected? 2. Repair or replace as necessary if a problem is Was a problem detected?
detected. detected.

Yes Yes
Go to step 12. Go to step 12.
Step 5 Step 5
1. Use the breaker box or DMM to check 1. Use the breaker box or DMM to check
whether the conditions below are present in whether the conditions below are present in
the circuit between the SCV and ECM. the circuit between the SCV and ECM.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection If there is no breaker box, see the Inspection
procedures for sensors on actual machine. procedures for sensors on actual machine.
• Short-circuit between terminals • Short-circuit between terminals
• Short circuit with power supply circuit or igni- No • Short circuit with power supply circuit or igni- No
tion power supply circuit Was a problem detected? tion power supply circuit Was a problem detected?
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. Yes detected. Yes
Go to step 12. Go to step 12.

Step 6 Step 6
Inspect the SCV main unit. Inspect the SCV main unit.
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the harness from the SCV. 2. Remove the harness from the SCV.
3. Measure the resistance at the SCV connector Reference value 3. Measure the resistance at the SCV connector Reference value
terminal. tween terminals: 3.2 ± 0.3 Ω terminal. tween terminals: 3.2 ± 0.3 Ω
BeBetween each terminal and the SCV body: ∞Ω (during BeBetween each terminal and the SCV body: ∞Ω (during
No normal temperatures) No normal temperatures)
Is the resistance at the reference value? Is the resistance at the reference value?

Yes Yes
Step 7 Go to step 8. Step 7 Go to step 8.
Replace the supply pump (SCV). Replace the supply pump (SCV).
Note: Note:
See the “Engine” section in the Service Manual See the “Engine” section in the Service Manual
for the work procedures. for the work procedures.

Is the action complete? Is the action complete?

Yes Yes
Go to step 12. Go to step 12.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-19 4021-19

Step 8 From step 6 Step 8 From step 6


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
(See the service support DIAG (trouble diagnosis) (See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes.) codes.)
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Start the engine and perform a test drive under the 4. Start the engine and perform a test drive under the
“Preconditions when diagnostic trouble code is set”. “Preconditions when diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

No Go to No Go to
Was a diagnostic trouble code detected? Was a diagnostic trouble code detected?
diagnostic aid. diagnostic aid.
Step 10 Step 10
1. Check the ECM software version. 1. Check the ECM software version.
Yes Yes
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, Step 9 For details on checking the ECM and the rewriting, Step 9
Go to step 11. Go to step 11.
see “How to Use EMPS”. Is there an EMPS? see “How to Use EMPS”. Is there an EMPS?
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. Yes perform EGR learning. Yes
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
No No
2. Turn the key switch “OFF”. Is the action complete? 2. Turn the key switch “OFF”. Is the action complete?
3. Wait about 10 sec. 3. Wait about 10 sec.

Yes Yes

Step 11 Is the action complete? Step 11 Is the action complete?


Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] Yes [EGR learning method] Yes
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
No No
Has a diagnostic trouble code: 0090 been detected? Has a diagnostic trouble code: 0090 been detected?

Step 12 Yes Step 12 Yes


Go to step 2. Go to step 2.
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
Connect all harnesses. Connect all harnesses.
Delete the diagnostic trouble code. Delete the diagnostic trouble code.
(See the service support DIAG (trouble diagnosis) (See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes.) codes.)
Turn the key switch “OFF” for at least 10 sec. No Turn the key switch “OFF” for at least 10 sec. No
Start the engine and perform a test drive under the Has any other diagnostic trouble code been detected? Check repair. Start the engine and perform a test drive under the Has any other diagnostic trouble code been detected? Check repair.
“Preconditions when diagnostic trouble code is set”. “Preconditions when diagnostic trouble code is set”.
Confirm the diagnostic trouble code. Yes Confirm the diagnostic trouble code. Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Step 13 Step 13
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-20 4021-20
Block diagram Block diagram

SUCTION CONT. VALVE SUCTION CONT. VALVE

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Main relay power supply voltage is 18 V or higher. • Main relay power supply voltage is 18 V or higher.
• DTC: 0090 is not detected. • DTC: 0090 is not detected.
• Engine speed is at least 300 min-1 or actual common rail pressure is at or above target common rail pressure. • Engine speed is at least 300 min-1 or actual common rail pressure is at or above target common rail pressure.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-21 4021-21
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
105-SCV terminal 105-SCV terminal
Resistance • Remove the SCV con- Resistance • Remove the SCV con-
Disconnection/ 113-SCV terminal 5 Ω or 10 M Ω or Disconnection/ 113-SCV terminal 5 Ω or 10 M Ω or
measure- nector. measure- nector.
high resistance 89-SCV terminal lower higher high resistance 89-SCV terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
97-SCV terminal 97-SCV terminal
4 4
105-GND 105-GND
Resistance • Remove the SCV con- Resistance • Remove the SCV con-
113-GND 10 M Ω 100 Ω or 113-GND 10 M Ω 100 Ω or
Short circuit with GND measure- nector. Short circuit with GND measure- nector.
89-GND or higher lower 89-GND or higher lower
ment • Key switch "OFF" ment • Key switch "OFF"
97-GND 97-GND
105-89 105-89
Resistance • Remove the SCV con- Resistance • Remove the SCV con-
Short-circuit between 105-97 10 M Ω 100 Ω or Short-circuit between 105-97 10 M Ω 100 Ω or
measure- nector. measure- nector.
terminals 113-89 or higher lower terminals 113-89 or higher lower
ment • Key switch "OFF" ment • Key switch "OFF"
113-97 113-97
105-GND 105-GND
Voltage • Remove the SCV con- Voltage • Remove the SCV con-
Short circuit with power 113-GND 18 V or Short circuit with power 113-GND 18 V or
5 value mea- nector. 0V 5 value mea- nector. 0V
supply circuit 89-GND higher supply circuit 89-GND higher
surement • Key switch "ON" surement • Key switch "ON"
97-GND 97-GND
105-GND 105-GND
Voltage • Remove the SCV con- Voltage • Remove the SCV con-
Short circuit with other 113-GND 1 V or Short circuit with other 113-GND 1 V or
value mea- nector. 0V value mea- nector. 0V
signal circuit 89-GND higher signal circuit 89-GND higher
surement • Key switch "ON" surement • Key switch "ON"
97-GND 97-GND

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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4021-22 4021-22
DTC: 0107 DTC: 0107
Atmospheric Pressure Sensor Circuit Abnormality (abnormally low voltage) Atmospheric Pressure Sensor Circuit Abnormality (abnormally low voltage)

Black smoke at high altitude Black smoke at high altitude


Insufficient output at low altitude Insufficient output at low altitude

Step 1 Step 1
Perform an actual machine diagnosis service Perform an actual machine diagnosis service
support check. support check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check

Yes Yes

Step 3 Step 3
Use the scan tool to check the atmospheric No Use the scan tool to check the atmospheric No
pressure sensor value. Step 2 pressure sensor value. Step 2
Go to step 14. Go to step 14.
1. Connect the scan tool. Do you have a scan tool (KW communication)? 1. Connect the scan tool. Do you have a scan tool (KW communication)?
2. Start the engine. 2. Start the engine.
3. Use the scan tool to check the Yes 3. Use the scan tool to check the Yes
“Barometric Pressure Sensor” display. “Barometric Pressure Sensor” display.

Reference value No Reference value No


0.5V Go to diagnostic aid. 0.5V Go to diagnostic aid.
Step 4 Step 4
Is the “Barometric Pressure Sensor” Is the “Barometric Pressure Sensor”
Check the installation status of the atmospheric Check the installation status of the atmospheric
value at or below the reference value? value at or below the reference value?
pressure sensor, the ECM and the intermediate pressure sensor, the ECM and the intermediate
connector. connector.
1. Inspect whether there is any backlash or 1. Inspect whether there is any backlash or
Yes Yes
looseness in the installation of the looseness in the installation of the
connectors. connectors.
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. No detected. No
Was a problem detected? Was a problem detected?

Step 5 Yes Step 5 Yes


1. Turn the key switch “OFF”. Go to step 9. 1. Turn the key switch “OFF”. Go to step 9.
2. Remove the atmospheric pressure sensor 2. Remove the atmospheric pressure sensor
connector. connector.
3. Use a jumper cable to create a short circuit 3. Use a jumper cable to create a short circuit
between the power supply terminal of the between the power supply terminal of the
atmospheric pressure sensor connector and atmospheric pressure sensor connector and
the signal terminal. the signal terminal.
4. Turn the key switch “ON”. 4. Turn the key switch “ON”.
5. Use the scan tool to check the “Barometric Reference value 5. Use the scan tool to check the “Barometric Reference value
No No
Pressure Sensor” display. 4.8 V Pressure Sensor” display. 4.8 V
Is the “Barometric Pressure Sensor” value at or above Is the “Barometric Pressure Sensor” value at or above
the reference value? the reference value?

Step 6 Yes Step 6 Yes


1. Use the breaker box or DMM to check Go to step 8. 1. Use the breaker box or DMM to check Go to step 8.
whether the conditions below are present in whether the conditions below are present in
the power supply circuit between the ECM the power supply circuit between the ECM
and atmospheric pressure sensor. and atmospheric pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection No If there is no breaker box, see the Inspection No
procedures for sensors on actual machine. Was a problem detected? procedures for sensors on actual machine. Was a problem detected?
• Disconnection • Disconnection
• High resistance • High resistance
Yes Yes
2. Repair or replace as necessary if a problem is Go to step 9. 2. Repair or replace as necessary if a problem is Go to step 9.
detected. detected.

Step 7 Step 7
1. Use the breaker box or DMM to check 1. Use the breaker box or DMM to check
whether the conditions below are present in whether the conditions below are present in
the signal circuit between the ECM and No the signal circuit between the ECM and No
atmospheric pressure sensor. Was a problem detected? atmospheric pressure sensor. Was a problem detected?
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection Yes If there is no breaker box, see the Inspection Yes
Go to step 12. Go to step 12.
procedures for sensors on actual machine. procedures for sensors on actual machine.
• Short circuit with atmospheric pressure sen- • Short circuit with atmospheric pressure sen-
sor GND circuit sor GND circuit
Short circuit with GND Short circuit with GND
• Disconnection • Disconnection
• High resistance • High resistance
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.
Go to step 9. Go to step 9.

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4021-23 4021-23

From step 5 From step 6 and 7 From step 5 From step 6 and 7

Step 8 Step 8
Replace the atmospheric pressure sensor. Replace the atmospheric pressure sensor.

Is the action complete? Is the action complete?

Step 10 Yes Step 10 Yes


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software version is 2. Perform rewriting if updating the ECM software version is
necessary. necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
“How to Use EMPS” in this chapter. No “How to Use EMPS” in this chapter. No
Step 9 Step 9
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. Yes 1. Turn the key switch “ON”. Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Yes Yes
Step 11 Step 11
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Is the action complete? 3. Wait about 10 sec. Is the action complete?

Step 12 Step 12
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
(See the service support DIAG (trouble diagnosis) screen No Has a diagnostic trouble code: 0107 been (See the service support DIAG (trouble diagnosis) screen No Has a diagnostic trouble code: 0107 been
for information on deleting diagnostic trouble codes.) detected? for information on deleting diagnostic trouble codes.) detected?
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when Yes 4. Perform a test drive under the “Preconditions when Yes
diagnostic trouble code is set”. Go to step 2. diagnostic trouble code is set”. Go to step 2.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 13 Step 13
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

From step 2 From step 2

Step 14 Step 14
1. Start the engine. 1. Start the engine.
2. Check the “Barometric Pressure” display. 2. Check the “Barometric Pressure” display.

Reference value No Reference value No


127 kPa (error display value) Go to diagnostic 127 kPa (error display value) Go to diagnostic
Is the “Barometric Pressure” display showing the aid. Is the “Barometric Pressure” display showing the aid.
Step 15 Step 15
error display value? error display value?
Check the installation status of the atmospheric pressure Check the installation status of the atmospheric pressure
sensor, the ECM and the intermediate connector. sensor, the ECM and the intermediate connector.
(Inspect for disconnection or a GND short in the atmospheric Yes (Inspect for disconnection or a GND short in the atmospheric Yes
pressure sensor circuit) pressure sensor circuit)
1. Inspect whether there is any disconnection, backlash or 1. Inspect whether there is any disconnection, backlash or
looseness in the installation of the connectors. No looseness in the installation of the connectors. No
2. Repair or replace as necessary if a problem is detected. Was a problem detected? 2. Repair or replace as necessary if a problem is detected. Was a problem detected?

Yes Yes

Go to step 16. Go to step 16.

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4021-24 4021-24

Step 16 From step 15 Step 16 From step 15


1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the power supply circuit conditions below are present in the power supply circuit
between the ECM and atmospheric pressure sensor. between the ECM and atmospheric pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. sensors on actual machine.
• Disconnection • Disconnection
• High resistance No • High resistance No
Was a problem detected? Was a problem detected?
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

Yes Yes
Go to step 12. Go to step 12.
Step 17 Step 17
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit between conditions below are present in the signal circuit between
the ECM and atmospheric pressure sensor. the ECM and atmospheric pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures for Was a problem detected? If there is no breaker box, see the Inspection procedures for Was a problem detected?
sensors on actual machine. sensors on actual machine.
• Short circuit with atmospheric pressure sensor GND circuit • Short circuit with atmospheric pressure sensor GND circuit
Short circuit with GND Yes Short circuit with GND Yes
• Disconnection Go to step 12. • Disconnection Go to step 12.
• High resistance • High resistance
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

Go to step 8. Go to step 8.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-25 4021-25
Block diagram Block diagram

BARO SENSOR BARO SENSOR

AIR INTAKE TEMP. SENSOR AIR INTAKE TEMP. SENSOR

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630, 1632 are not detected. • DTC: 1630, 1632 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-26 4021-26
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 61-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 61-Sensor connector 100 Ω or 10 M Ω or
6 measure- connector. 6 measure- connector.
high resistance power supply terminal lower higher high resistance power supply terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
Resistance • Remove the sensor Resistance • Remove the sensor
Short circuit with GND 71-60 10 M Ω 100 Ω or Short circuit with GND 71-60 10 M Ω 100 Ω or
measure- connector. measure- connector.
circuit/GND 71-GND or higher lower circuit/GND 71-GND or higher lower
ment • Key switch "OFF" ment • Key switch "OFF"
7 7
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 71-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 71-Sensor connector 100 Ω or 10 M Ω or
measure- connector. measure- connector.
high resistance signal terminal lower higher high resistance signal terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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4021-27 4021-27
DTC: 0108 DTC: 0108
Atmospheric Pressure Sensor Circuit Abnormality (abnormally high voltage) Atmospheric Pressure Sensor Circuit Abnormality (abnormally high voltage)

Black smoke at high altitude Black smoke at high altitude


Insufficient output at low altitude Insufficient output at low altitude

Step 1 Step 1
Perform an actual machine diagnosis service Perform an actual machine diagnosis service
support check. support check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check

Yes Yes

Step 3 Step 3
Use the scan tool to check the atmospheric No Use the scan tool to check the atmospheric No
pressure sensor value. Step 2 pressure sensor value. Step 2
Go to step 14. Go to step 14.
1. Connect the scan tool. Do you have a scan tool (KW communication)? 1. Connect the scan tool. Do you have a scan tool (KW communication)?
2. Start the engine. 2. Start the engine.
3. Use the scan tool to check the Yes 3. Use the scan tool to check the Yes
“Barometric Pressure Sensor” display. “Barometric Pressure Sensor” display.

Reference value No Reference value No


3.8 V Go to diagnostic aid. 3.8 V Go to diagnostic aid.
Step 4 Step 4
Is the “Barometric Pressure Sensor” Is the “Barometric Pressure Sensor”
Check the installation status of the atmospheric Check the installation status of the atmospheric
value at or above the reference value? value at or above the reference value?
pressure sensor, the ECM and the intermediate pressure sensor, the ECM and the intermediate
connector. connector.
1. Inspect whether there is any backlash or 1. Inspect whether there is any backlash or
Yes Yes
looseness in the installation of the looseness in the installation of the
connectors. connectors.
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. No detected. No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 12. Go to step 12.
Step 5 Step 5
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the atmospheric pressure sensor 2. Remove the atmospheric pressure sensor
connector. connector.
3. Turn the key switch “ON”. 3. Turn the key switch “ON”.
4. Use the scan tool to check the “Barometric 4. Use the scan tool to check the “Barometric
Pressure Sensor” display. Pressure Sensor” display.
No Reference value No Reference value
0V 0V
Is the “Barometric Pressure Sensor” value at or below Is the “Barometric Pressure Sensor” value at or below
the reference value? the reference value?

Yes Yes
Step 6 Go to step 8. Step 6 Go to step 8.
1. Use the breaker box or DMM to inspect 1. Use the breaker box or DMM to inspect
whether there is a short circuit with the whether there is a short circuit with the
electrical circuit or ignition power supply electrical circuit or ignition power supply
circuit in the signal circuit between the ECM circuit in the signal circuit between the ECM
and atmospheric pressure sensor. and atmospheric pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
Was a problem detected? Was a problem detected?
If there is no breaker box, see the Inspection If there is no breaker box, see the Inspection
procedures for sensors on actual machine. procedures for sensors on actual machine.
Important: Yes Important: Yes
If the atmospheric pressure sensor circuit is Go to step 12. If the atmospheric pressure sensor circuit is Go to step 12.
short-circuited to the power supply circuit, there short-circuited to the power supply circuit, there
may be sensors that are damaged. may be sensors that are damaged.
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

Step 7 Step 7
1. Use the breaker box or DMM to check 1. Use the breaker box or DMM to check
No No
whether the conditions below are present in Was a problem detected? whether the conditions below are present in Was a problem detected?
the GND circuit between the ECM and the GND circuit between the ECM and
atmospheric pressure sensor. atmospheric pressure sensor.
See the Breaker Box Inspection Procedure. Yes See the Breaker Box Inspection Procedure. Yes
Note: Go to step 12. Note: Go to step 12.
If there is no breaker box, see the Inspection If there is no breaker box, see the Inspection
procedures for sensors on actual machine. procedures for sensors on actual machine.
• Disconnection • Disconnection
• High resistance • High resistance
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

Go to step 9. Go to step 9.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-28 4021-28

From step 5 From step 7 From step 5 From step 7

Step 8 Step 8
Replace the atmospheric pressure sensor. Replace the atmospheric pressure sensor.

Is the action complete? Is the action complete?

Step Yes Step Yes


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software version is 2. Perform rewriting if updating the ECM software version is
necessary. necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
“How to Use EMPS”. No “How to Use EMPS”. No
Step 9 Step 9
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. Yes 1. Turn the key switch “ON”. Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. No 3. Wait about 10 sec. No
Is the action complete? Is the action complete?

Yes Yes
Step 11 Step 11
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Is the action complete? 3. Wait about 10 sec. Is the action complete?

Yes Yes

Step 12 Step 12
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
(See the service support DIAG (trouble diagnosis) screen No Has a diagnostic trouble code: 0108 been (See the service support DIAG (trouble diagnosis) screen No Has a diagnostic trouble code: 0108 been
for information on deleting diagnostic trouble codes.) detected? for information on deleting diagnostic trouble codes.) detected?
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when Yes 4. Perform a test drive under the “Preconditions when Yes
diagnostic trouble code is set”. Go to step 2. diagnostic trouble code is set”. Go to step 2.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 13 Step 13
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

From step 2 From step 2


Step 14 Step 14
1. Start the engine. 1. Start the engine.
2. Check the “Barometric Pressure” display. 2. Check the “Barometric Pressure” display.

Reference value No Reference value No


127 kPa (error display value) Go to diagnostic aid. 127 kPa (error display value) Go to diagnostic aid.
Step 15 Is the “Barometric Pressure” display showing the Step 15 Is the “Barometric Pressure” display showing the
Check the installation status of the atmospheric pressure error display value or higher? Check the installation status of the atmospheric pressure error display value or higher?
sensor, the ECM and the intermediate connector. sensor, the ECM and the intermediate connector.
(Inspect for a short circuit in the +5 V line of the atmospheric (Inspect for a short circuit in the +5 V line of the atmospheric
pressure sensor circuit or in the battery power supply circuit) pressure sensor circuit or in the battery power supply circuit)
Inspect whether there is any, backlash or looseness in the Inspect whether there is any, backlash or looseness in the
installation of the connectors. Yes installation of the connectors. Yes
Repair or replace as necessary if a problem is detected. Repair or replace as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?

Yes Yes

Go to step 16. Go to step 16.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-29 4021-29

Step 16 From step 15 Step 16 From step 15


1. Use the breaker box or DMM to inspect whether there is a 1. Use the breaker box or DMM to inspect whether there is a
short circuit with the power supply circuit or ignition power short circuit with the power supply circuit or ignition power
supply circuit in the signal circuit between the ECM and supply circuit in the signal circuit between the ECM and
atmospheric pressure sensor. atmospheric pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. sensors on actual machine.
Important: If the atmospheric pressure sensor circuit is short- No Important: If the atmospheric pressure sensor circuit is short- No
circuited to the power supply circuit, there may be sensors that circuited to the power supply circuit, there may be sensors that
Was a problem detected? Was a problem detected?
are damaged. are damaged.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Yes Yes
Go to step 12. Go to step 12.
Step 17 Step 17
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the GND circuit between the conditions below are present in the GND circuit between the
ECM and atmospheric pressure sensor. ECM and atmospheric pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures for Was a problem detected? If there is no breaker box, see the Inspection procedures for Was a problem detected?
sensors on actual machine. sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
Go to step 12. Go to step 12.
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

Go to step 8. Go to step 8.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-30 4021-30
Block diagram Block diagram

BARO SENSOR BARO SENSOR

AIR INTAKE TEMP. SENSOR AIR INTAKE TEMP. SENSOR

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630, 1632 are not detected. • DTC: 1630, 1632 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-31 4021-31
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with power 18 V or Short circuit with power 18 V or
6 value mea- connector. 71-GND 0V 6 value mea- connector. 71-GND 0V
supply circuit higher supply circuit higher
surement • Key switch "ON" surement • Key switch "ON"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 60-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 60-Sensor connector 100 Ω or 10 M Ω or
7 measure- connector. 7 measure- connector.
high resistance GND terminal lower higher high resistance GND terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"

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4021-32 4021-32
DTC: 0112 DTC: 0112
IAT (suction air temperature) Sensor Abnormality (abnormally low voltage) IAT (suction air temperature) Sensor Abnormality (abnormally low voltage)

Possibility of white smoke when starting at low Possibility of white smoke when starting at low
temperature temperature

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check

Yes Yes

Step 3 No Step 3 No
Use the scan tool to check the IAT sensor value. Step 2 Use the scan tool to check the IAT sensor value. Step 2
Go to step 13. Go to step 13.
1. Connect the scan tool. Do you have a scan tool (KW communication)? 1. Connect the scan tool. Do you have a scan tool (KW communication)?
2. Start the engine. 2. Start the engine.
3. Use the scan tool to check the “IAT sensor” display. Yes 3. Use the scan tool to check the “IAT sensor” display. Yes

Reference value No Reference value No


0.1 V Go to diagnostic aid. 0.1 V Go to diagnostic aid.
Step 4 Is the “IAT sensor” value at or below the Step 4 Is the “IAT sensor” value at or below the
Check the installation status of the IAT sensor, the ECM reference value? Check the installation status of the IAT sensor, the ECM reference value?
and the intermediate connector. and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. Yes the installation of the connectors. Yes
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 11. Go to step 11.
Step 5 Step 5
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the IAT sensor connector. 2. Remove the IAT sensor connector.
3. Turn the key switch “ON”. 3. Turn the key switch “ON”.
4. Use the scan tool to check the “IAT Sensor” display. 4. Use the scan tool to check the “IAT Sensor” display.
No Reference value No Reference value
4.8 V 4.8 V
Is the “IAT sensor” value at or above the Is the “IAT sensor” value at or above the
reference value? reference value?

Step 6 Yes Step 6 Yes


1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and IAT sensor. between the ECM and IAT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. No for sensors on actual machine. No
• Short circuit with IAT sensor GND circuit Was a problem detected? • Short circuit with IAT sensor GND circuit Was a problem detected?
• Short circuit with GND • Short circuit with GND
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. Yes detected. Yes
Go to step 11. Go to step 11.

Go to step 8. Go to step 8.

Step 7 Step 7
Replace the IAT sensor. Replace the IAT sensor.

Is the action complete? Is the action complete?

Yes Yes

Go to step 11. Go to step 11.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-33 4021-33

From step 6 From step 6

Step 9 Step 9
1. Check the ECM software version. 1. Check the ECM software version.
No Step 8 No Step 8
2. Perform rewriting if updating the ECM software version is 2. Perform rewriting if updating the ECM software version is
necessary. Is there an EMPS? necessary. Is there an EMPS?
For details on checking the ECM and the rewriting, see “How to For details on checking the ECM and the rewriting, see “How to
Use EMPS”. Yes Use EMPS”. Yes
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] No [EGR learning method] No
1. Turn the key switch “ON”. Is the action complete? 1. Turn the key switch “ON”. Is the action complete?
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Yes 3. Wait about 10 sec. Yes

Step 10 Step 10
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. Is the action complete? 1. Turn the key switch “ON”. Is the action complete?
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Yes Yes

Step 11 Step 11
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
(See the service support DIAG (trouble diagnosis) screen No Has a diagnostic trouble code: 0112 been (See the service support DIAG (trouble diagnosis) screen No Has a diagnostic trouble code: 0112 been
for information on deleting diagnostic trouble codes.) detected? for information on deleting diagnostic trouble codes.) detected?
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when Yes 4. Perform a test drive under the “Preconditions when Yes
diagnostic trouble code is set”. Go to step 3. diagnostic trouble code is set”. Go to step 3.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 12 Step 12
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

From step 2 From step 2


Step 13 Step 13
1. Start the engine. 1. Start the engine.
2. Check the “Intake Air Temperature” display. 2. Check the “Intake Air Temperature” display.

Reference value Reference value


214 °C 214 °C
Step 14 (error display value) No Step 14 (error display value) No
Check the installation status of the IAT sensor, the ECM and Is the “Intake Air Temperature” display showing the Go to diagnostic aid. Check the installation status of the IAT sensor, the ECM and Is the “Intake Air Temperature” display showing the Go to diagnostic aid.
the intermediate connector. error display value? the intermediate connector. error display value?
(Inspect for a GND short in the IAT sensor circuit) (Inspect for a GND short in the IAT sensor circuit)
1. Inspect whether there is any backlash or looseness in the Yes 1. Inspect whether there is any backlash or looseness in the Yes
installation of the connectors. installation of the connectors.
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 11. Go to step 11.

Go to step 15. Go to step 15.

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4021-34 4021-34

Step 15 From step 14 Step 15 From step 14


1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit between conditions below are present in the signal circuit between
the ECM and IAT sensor. the ECM and IAT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures for Was a problem detected? If there is no breaker box, see the Inspection procedures for Was a problem detected?
sensors on actual machine. sensors on actual machine.
• Short circuit with IAT sensor GND circuit • Short circuit with IAT sensor GND circuit
• Short circuit with GND Yes • Short circuit with GND Yes
Go to step 11. Go to step 11.
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

Go to step 7. Go to step 7.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-35 4021-35
Block diagram Block diagram

BARO SENSOR BARO SENSOR

AIR INTAKE TEMP. SENSOR AIR INTAKE TEMP. SENSOR

65*- 65*-

Recovery from failure Recovery from failure


3 - 10 min. required for trouble judgment. 3 - 10 min. required for trouble judgment.
Preconditions when DTC is set Preconditions when DTC is set
• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630, 1632 are not detected. • DTC: 1630, 1632 are not detected.
Diagnostic aid Diagnostic aid
• In order to check the performance of the IAT sensor, use the suction air temperature-resistance graph to perform inspection • In order to check the performance of the IAT sensor, use the suction air temperature-resistance graph to perform inspection
at various temperatures. When there is a sensor abnormality, this may have an effect on operation performance. at various temperatures. When there is a sensor abnormality, this may have an effect on operation performance.
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-36 4021-36
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance • Remove the sensor Resistance • Remove the sensor
Short circuit with GND 72-60 10 M Ω 100 Ω or Short circuit with GND 72-60 10 M Ω 100 Ω or
6 measure- connector. 6 measure- connector.
circuit/GND 72-GND or higher lower circuit/GND 72-GND or higher lower
ment • Key switch "OFF" ment • Key switch "OFF"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

INTAKE AIR TEMPERATURE - RESISTANCE TABLE INTAKE AIR TEMPERATURE - RESISTANCE TABLE
㪈㪇㪇㪇 㪈㪇㪇㪇

㪈㪇㪇 㪈㪇㪇

㪈㪇 㪈㪇
RESISTANCE (kΩ)

RESISTANCE (kΩ)
㪈 㪈

㪇㪅㪈 㪇㪅㪈

㪇㪅㪇㪈 㪇㪅㪇㪈
㪄㪋㪇 㪄㪊㪇 㪄㪉㪇 㪄㪈㪇 㪇 㪈㪇 㪉㪇 㪊㪇 㪋㪇 㪌㪇 㪍㪇 㪎㪇 㪏㪇 㪐㪇 㪈㪇㪇 㪈㪈㪇 㪈㪉㪇 㪈㪊㪇 㪈㪋㪇 㪈㪌㪇 㪄㪋㪇 㪄㪊㪇 㪄㪉㪇 㪄㪈㪇 㪇 㪈㪇 㪉㪇 㪊㪇 㪋㪇 㪌㪇 㪍㪇 㪎㪇 㪏㪇 㪐㪇 㪈㪇㪇 㪈㪈㪇 㪈㪉㪇 㪈㪊㪇 㪈㪋㪇 㪈㪌㪇

INTAKE AIR TEMPERATURE °C 659) INTAKE AIR TEMPERATURE °C 659)

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-37 4021-37
DTC: 0113 DTC: 0113
IAT (suction air temperature) Sensor Abnormality (abnormally high voltage) IAT (suction air temperature) Sensor Abnormality (abnormally high voltage)

Possibility of white smoke when starting at low Possibility of white smoke when starting at low
temperature temperature

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check

Yes Yes

Step 3 No Step 3 No
Use the scan tool to check the IAT sensor value. Step 2 Use the scan tool to check the IAT sensor value. Step 2
Go to step 15. Go to step 15.
1. Connect the scan tool. Do you have a scan tool (KW communication)? 1. Connect the scan tool. Do you have a scan tool (KW communication)?
2. Start the engine. 2. Start the engine.
3. Use the scan tool to check the “IAT sensor” display. Yes 3. Use the scan tool to check the “IAT sensor” display. Yes

Reference value No Reference value No


4.95 V Go to diagnostic aid. 4.95 V Go to diagnostic aid.
Step 4 Is the “IAT sensor” value at or above the Step 4 Is the “IAT sensor” value at or above the
Check the installation status of the IAT sensor, the ECM reference value? Check the installation status of the IAT sensor, the ECM reference value?
and the intermediate connector. and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. Yes the installation of the connectors. Yes
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 5 Step 5
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the IAT sensor connector. 2. Remove the IAT sensor connector.
3. Use a jumper cable to create a short circuit between 3. Use a jumper cable to create a short circuit between
the signal terminal of the IAT sensor connector and the signal terminal of the IAT sensor connector and
the GND terminal. the GND terminal.
4. Turn the key switch “ON”. Reference value 4. Turn the key switch “ON”. Reference value
No 0V No 0V
5. Use the scan tool to check the “IAT Sensor” display. 5. Use the scan tool to check the “IAT Sensor” display.
Is the “IAT sensor” value at or below the Is the “IAT sensor” value at or below the
reference value? reference value?

Step 6 Yes Step 6 Yes


1. Use the breaker box or DMM to inspect whether there Go to step 9. 1. Use the breaker box or DMM to inspect whether there Go to step 9.
is a short circuit with the power supply circuit or is a short circuit with the power supply circuit or
ignition power supply circuit in the signal circuit ignition power supply circuit in the signal circuit
between the ECM and IAT sensor. between the ECM and IAT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures No If there is no breaker box, see the Inspection procedures No
for sensors on actual machine. Was a problem detected? for sensors on actual machine. Was a problem detected?
Important: Important:
If the IAT sensor circuit is short-circuited to the power If the IAT sensor circuit is short-circuited to the power
Yes Yes
supply circuit, there may be sensors that are damaged. Go to step 13. supply circuit, there may be sensors that are damaged. Go to step 13.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 7 Step 7
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and IAT sensor. No between the ECM and IAT sensor. No
See the Breaker Box Inspection Procedure. Is the action complete? See the Breaker Box Inspection Procedure. Is the action complete?
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. Yes for sensors on actual machine. Yes
• Disconnection Go to step 13. • Disconnection Go to step 13.
• High resistance • High resistance
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Go to step 8. Go to step 8.

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4021-38 4021-38

Step 8 Step 8
1. Use the breaker box or DMM to check whether the From step 7 1. Use the breaker box or DMM to check whether the From step 7
conditions below are present in the GND circuit between the conditions below are present in the GND circuit between the
ECM and IAT sensor. ECM and IAT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. sensors on actual machine.
• Disconnection • Disconnection
• High resistance No • High resistance No
Was a problem detected? Was a problem detected?
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Yes Yes

From step 5, 19 From step 5, 19


Step 9 Step 9
Replace the IAT sensor. Replace the IAT sensor.

Is the action complete? Is the action complete?

Step 11 Yes Step 11 Yes


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software version is 2. Perform rewriting if updating the ECM software version is
necessary. necessary.
For details on checking the ECM and the rewriting, see “How to For details on checking the ECM and the rewriting, see “How to
Use EMPS”. No Use EMPS”. No
Step 10 Step 10
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 12 Step 12
Replace the ECM. Yes Replace the ECM. Yes
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Step 13 Yes Step 13 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
(See the service support DIAG (trouble diagnosis) screen (See the service support DIAG (trouble diagnosis) screen
for information on deleting diagnostic trouble codes.) No for information on deleting diagnostic trouble codes.) No
3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0113 been 3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0113 been
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 14 Step 14
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-39 4021-39

Step 15 From step 2 Step 15 From step 2


1. Start the engine. 1. Start the engine.
2. Check the “Intake Air Temperature” display. 2. Check the “Intake Air Temperature” display.
Because backup mode is entered after the trouble Because backup mode is entered after the trouble
judgment, the suction air temperature display is 214 °C. judgment, the suction air temperature display is 214 °C.

Reference value 214 °C (error display value) No Reference value 214 °C (error display value) No
Is the “Intake Air Temperature” display showing the Go to diagnostic aid. Is the “Intake Air Temperature” display showing the Go to diagnostic aid.
error display value? error display value?
Step 16 Step 16
Check the installation status of the IAT sensor, the ECM and Yes Check the installation status of the IAT sensor, the ECM and Yes
the intermediate connector. the intermediate connector.
1. Inspect whether there is any backlash or looseness in the 1. Inspect whether there is any backlash or looseness in the
installation of the connectors. installation of the connectors.
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

No No
Was a problem detected? . Was a problem detected? .
Step 17 Step 17
1. Use the breaker box or DMM to inspect whether there is a 1. Use the breaker box or DMM to inspect whether there is a
short circuit with the power supply circuit or ignition power Go to step 13. short circuit with the power supply circuit or ignition power Go to step 13.
supply circuit in the signal circuit between the ECM and IAT supply circuit in the signal circuit between the ECM and IAT
sensor. sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. sensors on actual machine.
Important: No Important: No
If the IAT sensor circuit is short-circuited to the power supply Was a problem detected? If the IAT sensor circuit is short-circuited to the power supply Was a problem detected?
circuit, there may be sensors that are damaged. circuit, there may be sensors that are damaged.
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 13. Go to step 13.

Step 18 Step 18
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit between conditions below are present in the signal circuit between
the ECM and IAT sensor. No the ECM and IAT sensor. No
See the Breaker Box Inspection Procedure. Was a problem detected? See the Breaker Box Inspection Procedure. Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. Yes sensors on actual machine. Yes
• Disconnection Go to step 13. • Disconnection Go to step 13.
• High resistance • High resistance
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

Step 19 Step 19
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the GND circuit between the conditions below are present in the GND circuit between the
ECM and IAT sensor. No ECM and IAT sensor. No
See the Breaker Box Inspection Procedure. Was a problem detected? See the Breaker Box Inspection Procedure. Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. Yes sensors on actual machine. Yes
• Disconnection Go to step 13. • Disconnection Go to step 13.
• High resistance • High resistance
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

Go to step 9. Go to step 9.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-40 4021-40
Block diagram Block diagram

BARO SENSOR BARO SENSOR

AIR INTAKE TEMP. SENSOR AIR INTAKE TEMP. SENSOR

65*- 65*-

Recovery from failure Recovery from failure


3 - 10 min. required for trouble judgment 3 - 10 min. required for trouble judgment
Preconditions when DTC is set Preconditions when DTC is set
• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630, 1632 are not detected. • DTC: 1630, 1632 are not detected.
• At least 3 min. passed after engine start. • At least 3 min. passed after engine start.
Diagnostic aid Diagnostic aid
• In order to check the performance of the IAT sensor, use the suction air temperature-resistance graph to perform inspection • In order to check the performance of the IAT sensor, use the suction air temperature-resistance graph to perform inspection
at various temperatures. When there is a sensor abnormality, this may have an effect on operation performance. at various temperatures. When there is a sensor abnormality, this may have an effect on operation performance.
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-41 4021-41
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with power 18 V or Short circuit with power 18 V or
6 value mea- connector. 72-GND 0V 6 value mea- connector. 72-GND 0V
supply circuit higher supply circuit higher
surement • Key switch "ON" surement • Key switch "ON"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 72-Sensor connector 100 M Ω 10 M Ω or Disconnection/ 72-Sensor connector 100 M Ω 10 M Ω or
7 measure- connector. 7 measure- connector.
high resistance signal terminal or lower higher high resistance signal terminal or lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 60-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 60-Sensor connector 100 Ω or 10 M Ω or
8 measure- connector. 8 measure- connector.
high resistance signal terminal lower higher high resistance signal terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.
INTAKE AIR TEMPERATURE - RESISTANCE TABLE INTAKE AIR TEMPERATURE - RESISTANCE TABLE

㪈㪇㪇㪇 㪈㪇㪇㪇

㪈㪇㪇 㪈㪇㪇

㪈㪇 㪈㪇
RESISTANCE (kΩ)

RESISTANCE (kΩ)
㪈 㪈

㪇㪅㪈 㪇㪅㪈

㪇㪅㪇㪈 㪇㪅㪇㪈
㪄㪋㪇 㪄㪊㪇 㪄㪉㪇 㪄㪈㪇 㪇 㪈㪇 㪉㪇 㪊㪇 㪋㪇 㪌㪇 㪍㪇 㪎㪇 㪏㪇 㪐㪇 㪈㪇㪇 㪈㪈㪇 㪈㪉㪇 㪈㪊㪇 㪈㪋㪇 㪈㪌㪇 㪄㪋㪇 㪄㪊㪇 㪄㪉㪇 㪄㪈㪇 㪇 㪈㪇 㪉㪇 㪊㪇 㪋㪇 㪌㪇 㪍㪇 㪎㪇 㪏㪇 㪐㪇 㪈㪇㪇 㪈㪈㪇 㪈㪉㪇 㪈㪊㪇 㪈㪋㪇 㪈㪌㪇
INTAKE AIR TEMPERATURE °C 659) INTAKE AIR TEMPERATURE °C 659)

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4021-42 4021-42
DTC: 0117 DTC: 0117
ECT (engine coolant temperature) Sensor Abnormality (abnormally low voltage) ECT (engine coolant temperature) Sensor Abnormality (abnormally low voltage)

Poor starting at low temperatures, black smoke Poor starting at low temperatures, black smoke
occurrence, and output reductions in some occurrence, and output reductions in some
cases cases

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check

Yes Yes

Step 3 No Step 3 No
Use the scan tool to check the ECT sensor value. Step 2 Use the scan tool to check the ECT sensor value. Step 2
Go to step 13. Go to step 13.
1. Connect the scan tool. Do you have a scan tool (KW communication)? 1. Connect the scan tool. Do you have a scan tool (KW communication)?
2. Start the engine. 2. Start the engine.
3. Use the scan tool to check the “ECT sensor” display. Yes 3. Use the scan tool to check the “ECT sensor” display. Yes

Reference value No Reference value No


0.1 V Go to diagnostic aid. 0.1 V Go to diagnostic aid.
Step 4 Is the “ECT sensor” value at or below the Step 4 Is the “ECT sensor” value at or below the
Check the installation status of the ECT sensor, the ECM reference value? Check the installation status of the ECT sensor, the ECM reference value?
and the intermediate connector. and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. Yes the installation of the connectors. Yes
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 11. Go to step 11.
Step 5 Step 5
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the ECT sensor connector. 2. Remove the ECT sensor connector.
3. Turn the key switch “ON”. 3. Turn the key switch “ON”.
4. Use the scan tool to check the “ECT Sensor” display. 4. Use the scan tool to check the “ECT Sensor” display.
No Reference value No Reference value
4.8 V 4.8 V
Is the “ECT sensor” value at or above the Is the “ECT sensor” value at or above the
reference value? reference value?

Step 6 Yes Step 6 Yes


1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and ECT sensor. between the ECM and ECT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. No for sensors on actual machine. No
• Short circuit with ECT sensor GND circuit Was a problem detected? • Short circuit with ECT sensor GND circuit Was a problem detected?
• Short circuit with GND • Short circuit with GND
2. Measure the ECT sensor resistance and check that 2. Measure the ECT sensor resistance and check that
Yes Yes
the measurement value is within the normal range. Go to step 11. the measurement value is within the normal range. Go to step 11.
3. Repair as necessary if a problem is detected. 3. Repair as necessary if a problem is detected.

Step 7 Step 7
Replace the ECT sensor. Replace the ECT sensor.

Is the action complete? Is the action complete?

Yes Yes
Go to step 11. Go to step 11.

No Step 8 No Step 8
Is there an EMPS? Is there an EMPS?

Yes Yes

Go to step 10. Go to step 9. Go to step 10. Go to step 9.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-43 4021-43

Step 9 Step 9
1. Check the ECM software version. 1. Check the ECM software version.
From step 8 From step 8
2. Perform rewriting if updating the ECM software version is 2. Perform rewriting if updating the ECM software version is
necessary. necessary.
For details on checking the ECM and the rewriting, see “How to For details on checking the ECM and the rewriting, see “How to
Use EMPS”. Use EMPS”.
Note: Note:
When ECM replacement or rewriting is performed, perform No When ECM replacement or rewriting is performed, perform No
EGR learning. Is the action complete? EGR learning. Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 10 Step 10
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
Is the action complete? Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Yes 3. Wait about 10 sec. Yes

Step 11 Step 11
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) screen for No Has a diagnostic trouble code: 0117 been See the service support DIAG (trouble diagnosis) screen for No Has a diagnostic trouble code: 0117 been
information on deleting diagnostic trouble codes.) detected? information on deleting diagnostic trouble codes.) detected?
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when Yes 4. Perform a test drive under the “Preconditions when Yes
diagnostic trouble code is set”. Go to step 2. diagnostic trouble code is set”. Go to step 2.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 12 Step 12
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

From step 2 From step 2


Step 13 Step 13
1. Start the engine. 1. Start the engine.
2. Check the “Engine coolant temperature” display. 2. Check the “Engine coolant temperature” display.
Because backup mode is entered after the trouble Because backup mode is entered after the trouble
judgment, the engine coolant temperature display is 214 °C. No Reference value 214 °C Yes judgment, the engine coolant temperature display is 214 °C. No Reference value 214 °C Yes
(error display value) Go to step 11. (error display value) Go to step 11.
Is the “Engine coolant temperature” display Is the “Engine coolant temperature” display
showing the error display value? showing the error display value?

Step 14 Step 14
Check the installation status of the ECT sensor, the ECM and Check the installation status of the ECT sensor, the ECM and
the intermediate connector. the intermediate connector.
1. Inspect whether there is any backlash or looseness in the 1. Inspect whether there is any backlash or looseness in the
installation of the connectors. installation of the connectors.
2. Repair or replace as necessary if a problem is detected. No 2. Repair or replace as necessary if a problem is detected. No
Is the action complete? Is the action complete?

Go to step 15. Go to step 15.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-44 4021-44

From step 14 From step 14

Step 15 Step 15
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit between conditions below are present in the signal circuit between
the ECM and engine coolant temperature sensor. No the ECM and engine coolant temperature sensor. No
See the Breaker Box Inspection Procedure. Is the action complete? See the Breaker Box Inspection Procedure. Is the action complete?
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. sensors on actual machine.
• Short circuit with engine coolant temperature sensor GND • Short circuit with engine coolant temperature sensor GND
circuit Go to step 7. circuit Go to step 7.
• Short circuit with GND • Short circuit with GND
2. Measure the ECT sensor resistance and check that the 2. Measure the ECT sensor resistance and check that the
measurement value is within the normal range. measurement value is within the normal range.
3. Repair or replace as necessary if a problem is detected. 3. Repair or replace as necessary if a problem is detected.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-45 4021-45
Block diagram Block diagram

OIL PRESS. SENSOR OIL PRESS. SENSOR

WATER TEMP. SENSOR WATER TEMP. SENSOR

FUEL TEMP. SENSOR FUEL TEMP. SENSOR

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Recovery from failure Recovery from failure


3 - 10 min. required for trouble judgment 3 - 10 min. required for trouble judgment
Preconditions when DTC is set Preconditions when DTC is set
• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630, 1633 are not detected. • DTC: 1630, 1633 are not detected.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-46 4021-46
Diagnostic aid Diagnostic aid
• A DTC is sometimes set during overheating. • A DTC is sometimes set during overheating.
• If the engine coolant temperature increases after the engine is started, the thermistor will begin to open (85 °C) and the • If the engine coolant temperature increases after the engine is started, the thermistor will begin to open (85 °C) and the
engine coolant temperature will stabilize. engine coolant temperature will stabilize.
• In order to check the performance of the ECT sensor, use the engine coolant temperature-resistance graph to perform • In order to check the performance of the ECT sensor, use the engine coolant temperature-resistance graph to perform
inspection at various temperatures. When there is a sensor abnormality, this may have an effect on operation performance. inspection at various temperatures. When there is a sensor abnormality, this may have an effect on operation performance.
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Breaker box inspection procedure Breaker box inspection procedure


For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance • Remove the sensor Resistance • Remove the sensor
Short circuit with GND 84-79 10 Ω or 100 Ω or Short circuit with GND 84-79 10 Ω or 100 Ω or
6,15 measure- connector. 6,15 measure- connector.
circuit/GND 84-GND higher lower circuit/GND 84-GND higher lower
ment • Key switch "OFF" ment • Key switch "OFF"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.
Engine coolant temperture - resistance table Engine coolant temperture - resistance table

 

 
Resistance (kΩ)

Resistance (kΩ)
 

 *%9#5*,  *%9#5*,


       
Engine coolant temperture °C Engine coolant temperture °C

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-47 4021-47
DTC: 0118 DTC: 0118
ECT (engine coolant temperature) Sensor Abnormality (abnormally high voltage) ECT (engine coolant temperature) Sensor Abnormality (abnormally high voltage)

Increase in noise, white smoke at low Increase in noise, white smoke at low
temperatures, unstable idling speed temperatures, unstable idling speed

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check

Yes Yes

Step 2 No Step 2 No
Step 3 Go to step 15. Step 3 Go to step 15.
Use the scan tool to check the ECT sensor value. Do you have a scan tool (KW communication)? Use the scan tool to check the ECT sensor value. Do you have a scan tool (KW communication)?
1. Connect the scan tool. 1. Connect the scan tool.
2. Start the engine. Yes 2. Start the engine. Yes
3. Use the scan tool to check the "ECT sensor" display. 3. Use the scan tool to check the "ECT sensor" display.

Reference value 4.85 V No Reference value 4.85 V No


Is the “ECT sensor” value at or above the Go to diagnostic aid. Is the “ECT sensor” value at or above the Go to diagnostic aid.
reference value? reference value?
Step 4 Step 4
Check the installation status of the ECT sensor, the ECM Yes Check the installation status of the ECT sensor, the ECM Yes
and the intermediate connector. and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is No 2. Repair or replace as necessary if a problem is No
detected. Was a problem detected? detected. Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 5 Step 5
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the ECT sensor connector. 2. Remove the ECT sensor connector.
3. Use a jumper cable to create a short circuit between 3. Use a jumper cable to create a short circuit between
the signal terminal of the ECT sensor connector and the signal terminal of the ECT sensor connector and
the GND terminal. No Reference value 0 V the GND terminal. No Reference value 0 V
4. Turn the key switch “ON”. Is the “ECT sensor” value at or below the 4. Turn the key switch “ON”. Is the “ECT sensor” value at or below the
5. Use the scan tool to check the “ECT sensor” display. reference value? 5. Use the scan tool to check the “ECT sensor” display. reference value?

Yes Yes
Go to step 9. Go to step 9.
Step 6 Step 6
1. Use the breaker box or DMM to inspect whether there 1. Use the breaker box or DMM to inspect whether there
is a short circuit with the power supply circuit or is a short circuit with the power supply circuit or
ignition power supply circuit in the signal circuit ignition power supply circuit in the signal circuit
between the ECM and ECT sensor. between the ECM and ECT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: Notes:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
Important: No Important: No
If the ECT sensor circuit is short-circuited to the power Was a problem detected? If the ECT sensor circuit is short-circuited to the power Was a problem detected?
supply circuit, there may be sensors that are damaged. supply circuit, there may be sensors that are damaged.
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 13. Go to step 13.

Step 7 Step 7
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and ECT sensor. between the ECM and ECT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: No Notes: No
Is the action complete? Is the action complete?
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
• Disconnection Yes • Disconnection Yes
• High resistance Go to step 13. • High resistance Go to step 13.
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

Go to step 8. Go to step 8.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-48 4021-48

Step 8 From step 7 Step 8 From step 7


1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and ECT sensor. between the ECM and ECT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: No Notes: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
2. Repair or replace as necessary if a problem is Go to step 13. 2. Repair or replace as necessary if a problem is Go to step 13.
detected. detected.

From step 5 From step 5

Step 9 Step 9
Replace the ECT sensor. Replace the ECT sensor.

Is the action complete? Is the action complete?

Yes Yes
Go to step 13. Go to step 13.
Step 11 Step 11
1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. No version is necessary. No
For details on checking the ECM and the rewriting, see Step 10 For details on checking the ECM and the rewriting, see Step 10
“How to Use EMPS”. Is there an EMPS? “How to Use EMPS”. Is there an EMPS?
Notes: Notes:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. Yes perform EGR learning. Yes
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
No No
2. Turn the key switch “OFF”. Is the action complete? 2. Turn the key switch “OFF”. Is the action complete?
3. Wait about 10 sec. 3. Wait about 10 sec.

Yes Yes
Go to step 13. Go to step 13.
Step 12 Step 12
Replace the ECM. Replace the ECM.
Notes: Notes:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. Is the action complete? 1. Turn the key switch “ON”. Is the action complete?
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Yes Yes

Step 13 Step 13
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. (See the service 2. Delete the diagnostic trouble code. (See the service
support DIAG (trouble diagnosis) screen for No Has a diagnostic trouble code: 0118 been support DIAG (trouble diagnosis) screen for No Has a diagnostic trouble code: 0118 been
information on deleting diagnostic trouble codes.) detected? information on deleting diagnostic trouble codes.) detected?
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when Yes 4. Perform a test drive under the “Preconditions when Yes
diagnostic trouble code is set”. Go to step 2. diagnostic trouble code is set”. Go to step 2.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 14 Step 14
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-49 4021-49

Step 15 From step 2 Step 15 From step 2


1. Start the engine. 1. Start the engine.
2. Check the “Engine coolant temperature” display. 2. Check the “Engine coolant temperature” display.
Because backup mode is entered after the trouble Because backup mode is entered after the trouble
judgment, the suction air temperature display is 214 °C. judgment, the suction air temperature display is 214 °C.

Reference value 214 °C (error display value) No Reference value 214 °C (error display value) No
Is the “Engine coolant temperature” display Go to diagnostic aid. Is the “Engine coolant temperature” display Go to diagnostic aid.
showing the error display value? showing the error display value?
Step 16 Step 16
Check the installation status of the ECT sensor, the ECM and Yes Check the installation status of the ECT sensor, the ECM and Yes
the intermediate connector. the intermediate connector.
1. Inspect whether there is any backlash or looseness in the 1. Inspect whether there is any backlash or looseness in the
installation of the connectors. installation of the connectors.
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?
Step 17 Step 17
1. Use the breaker box or DMM to inspect whether there is a 1. Use the breaker box or DMM to inspect whether there is a
Yes Yes
short circuit with the power supply circuit or ignition power Go to step 13. short circuit with the power supply circuit or ignition power Go to step 13.
supply circuit in the signal circuit between the ECM and supply circuit in the signal circuit between the ECM and
ECT sensor. ECT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. sensors on actual machine.
Important: No Important: No
If the ECT sensor circuit is short-circuited to the power supply Was a problem detected? If the ECT sensor circuit is short-circuited to the power supply Was a problem detected?
circuit, there may be sensors that are damaged. circuit, there may be sensors that are damaged.
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 13. Go to step 13.

Step 18 Step 18
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit between conditions below are present in the signal circuit between
the ECM and ECT sensor. the ECM and ECT sensor.
See the Breaker Box Inspection Procedure. No See the Breaker Box Inspection Procedure. No
Was a problem detected? Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. Yes sensors on actual machine. Yes
• Disconnection Go to step 13. • Disconnection Go to step 13.
• High resistance • High resistance
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

Step 19 Step 19
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the GND circuit between the conditions below are present in the GND circuit between the
ECM and ECT sensor. ECM and ECT sensor.
See the Breaker Box Inspection Procedure. No See the Breaker Box Inspection Procedure. No
Was a problem detected? Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. Yes sensors on actual machine. Yes
• Disconnection Go to step 13. • Disconnection Go to step 13.
• High resistance • High resistance
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

Go to step 9. Go to step 9.

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4021-50 4021-50
Block diagram Block diagram

OIL PRESS. SENSOR OIL PRESS. SENSOR

WATER TEMP. SENSOR WATER TEMP. SENSOR

FUEL TEMP. SENSOR FUEL TEMP. SENSOR

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Recovery from failure Recovery from failure


3 - 10 min. required for trouble judgment 3 - 10 min. required for trouble judgment
Preconditions when DTC is set Preconditions when DTC is set
• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630, 1633 are not detected. • DTC: 1630, 1633 are not detected.
• At least 3 min. passed after engine start. • At least 3 min. passed after engine start.

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4021-51 4021-51
Diagnostic aid Diagnostic aid
• If the engine coolant temperature increases after the engine is started, the thermistor will begin to open (85 °C) and the • If the engine coolant temperature increases after the engine is started, the thermistor will begin to open (85 °C) and the
engine coolant temperature will stabilize. engine coolant temperature will stabilize.
• In order to check the performance of the ECT sensor, use the engine coolant temperature-resistance graph to perform • In order to check the performance of the ECT sensor, use the engine coolant temperature-resistance graph to perform
inspection at various temperatures. When there is a sensor abnormality, this may have an effect on operation performance. inspection at various temperatures. When there is a sensor abnormality, this may have an effect on operation performance.
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Breaker box inspection procedure Breaker box inspection procedure


For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with power 18 V or Short circuit with power 18 V or
6 value mea- connector. 84-GND 0V 6 value mea- connector. 84-GND 0V
supply circuit higher supply circuit higher
surement • Key switch "ON" surement • Key switch "ON"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 84-Sensor connector 100 M Ω 10 M Ω or Disconnection/ 84-Sensor connector 100 M Ω 10 M Ω or
7 measure- connector. 7 measure- connector.
high resistance signal terminal or lower higher high resistance signal terminal or lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 79-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 79-Sensor connector 100 Ω or 10 M Ω or
8 measure- connector. 8 measure- connector.
high resistance GND terminal lower higher high resistance GND terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"

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4021-52 4021-52
Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.
Engine coolant temperture - resistance table Engine coolant temperture - resistance table

 

 
Resistance (kΩ)

Resistance (kΩ)
 

 *%9#5*,  *%9#5*,


       
Engine coolant temperture °C Engine coolant temperture °C

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4021-53 4021-53
DTC: 0182 DTC: 0182
FT (fuel temperature) Sensor Abnormality (abnormally low voltage) FT (fuel temperature) Sensor Abnormality (abnormally low voltage)

Possible impact on machine operability Possible impact on machine operability

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check

Yes Yes

Step 3 Step 2 No Step 3 Step 2 No


Use the scan tool to check the FT sensor value. Go to step 13. Use the scan tool to check the FT sensor value. Go to step 13.
Do you have a scan tool (KW communication)? Do you have a scan tool (KW communication)?
1. Connect the scan tool. 1. Connect the scan tool.
2. Start the engine. Yes 2. Start the engine. Yes
3. Use the scan tool to check the “Fuel temperature 3. Use the scan tool to check the “Fuel temperature
sensor” display. sensor” display.

Reference value 0.1 V No Reference value 0.1 V No


Is the “FT sensor” value at or below the Go to diagnostic aid. Is the “FT sensor” value at or below the Go to diagnostic aid.
reference value? reference value?
Step 4 Step 4
Check the installation status of the FT sensor, the ECM Yes Check the installation status of the FT sensor, the ECM Yes
and the intermediate connector. and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is No 2. Repair or replace as necessary if a problem is No
detected. Was a problem detected? detected. Was a problem detected?

Yes Yes
Go to step 11. Go to step 11.
Step 5 Step 5
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the FT sensor connector. 2. Remove the FT sensor connector.
3. Turn the key switch “ON”. 3. Turn the key switch “ON”.
4. Use the scan tool to check the “Fuel temperature 4. Use the scan tool to check the “Fuel temperature
sensor” display. No Reference value 4.8 V sensor” display. No Reference value 4.8 V
Is the “FT sensor” value at or above the Is the “FT sensor” value at or above the
reference value? reference value?

Step 6 Yes Step 6 Yes


1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and fuel temperature sensor. between the ECM and fuel temperature sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: Notes:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. No for sensors on actual machine. No
• Short circuit with FT sensor GND circuit Was a problem detected? • Short circuit with FT sensor GND circuit Was a problem detected?
• Short circuit with GND • Short circuit with GND
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 11. Go to step 11.

Step 7 Step 7
Replace the supply pump (FT sensor). Replace the supply pump (FT sensor).

Is the action complete? Is the action complete?

Yes Yes
Go to step 11. Go to step 11.

Go to step 8. Go to step 8.

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4021-54 4021-54

Step 9 From step 6 Step 9 From step 6


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software version is 2. Perform rewriting if updating the ECM software version is
necessary. No necessary. No
For details on checking the ECM and the rewriting, see “How to Step 8 For details on checking the ECM and the rewriting, see “How to Step 8
Use EMPS” in this chapter. Is there an EMPS? Use EMPS” in this chapter. Is there an EMPS?
Note: Note:
When ECM replacement or rewriting is performed, perform Yes When ECM replacement or rewriting is performed, perform Yes
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
No No
2. Turn the key switch “OFF”. Is the action complete? 2. Turn the key switch “OFF”. Is the action complete?
3. Wait about 10 sec. 3. Wait about 10 sec.

Yes Yes

Step 10 Step 10
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
Is the action complete? Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Yes 3. Wait about 10 sec. Yes

Step 11 Step 11
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) screen for No Has a diagnostic trouble code: 0182 been See the service support DIAG (trouble diagnosis) screen for No Has a diagnostic trouble code: 0182 been
information on deleting diagnostic trouble codes.) detected? information on deleting diagnostic trouble codes.) detected?
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when Yes 4. Perform a test drive under the “Preconditions when Yes
diagnostic trouble code is set”. Go to step 2. diagnostic trouble code is set”. Go to step 2.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 12 Step 12
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

From step 2 From step 2

Step 13 Step 13
1. Start the engine. 1. Start the engine.
2. Check the “Fuel temperature” display. 2. Check the “Fuel temperature” display.
Because backup mode is entered after the trouble Because backup mode is entered after the trouble
judgment, the engine coolant temperature display is 214 °C. No Reference value 214 °C No judgment, the engine coolant temperature display is 214 °C. No Reference value 214 °C No
(error display value) Go to diagnostic aid. (error display value) Go to diagnostic aid.
Is the “Fuel temperature” display showing the error Is the “Fuel temperature” display showing the error
display value? display value?

Step 14 Yes Step 14 Yes


Check the installation status of the FT sensor, the ECM and the Check the installation status of the FT sensor, the ECM and the
intermediate connector. intermediate connector.
1. Inspect whether there is any backlash or looseness in the 1. Inspect whether there is any backlash or looseness in the
installation of the connectors. installation of the connectors.
2. Repair or replace as necessary if a problem is detected. No 2. Repair or replace as necessary if a problem is detected. No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 11. Go to step 11.

Go to step 15. Go to step 15.

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4021-55 4021-55

Step 15 From step 14 Step 15 From step 14


1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit between conditions below are present in the signal circuit between
the ECM and FT sensor. the ECM and FT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures for Was a problem detected? If there is no breaker box, see the Inspection procedures for Was a problem detected?
sensors on actual machine. sensors on actual machine.
• Short circuit with FT sensor GND circuit • Short circuit with FT sensor GND circuit
• Short circuit with GND Yes • Short circuit with GND Yes
Go to step 11. Go to step 11.
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

Go to step 6. Go to step 6.

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4021-56 4021-56
Block diagram Block diagram

OIL PRESS. SENSOR OIL PRESS. SENSOR

WATER TEMP. SENSOR WATER TEMP. SENSOR

FUEL TEMP. SENSOR FUEL TEMP. SENSOR

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Recovery from failure Recovery from failure


3 - 10 min. required for trouble judgment. 3 - 10 min. required for trouble judgment.
Preconditions when DTC is set Preconditions when DTC is set
• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630, 1633 are not detected. • DTC: 1630, 1633 are not detected.

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4021-57 4021-57
Diagnostic aid Diagnostic aid
• Check that the temperature of the FT sensor and IAT (suction air temperature) sensor are close in value before starting • Check that the temperature of the FT sensor and IAT (suction air temperature) sensor are close in value before starting
when the engine is cool. when the engine is cool.
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Breaker box inspection procedure Breaker box inspection procedure


For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance • Remove the sensor Resistance • Remove the sensor
Short circuit with GND 83-109 10 M Ω 100 Ω or Short circuit with GND 83-109 10 M Ω 100 Ω or
6 measure- connector. 6 measure- connector.
circuit/GND 83-GND or higher lower circuit/GND 83-GND or higher lower
ment • Key switch "OFF" ment • Key switch "OFF"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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4021-58 4021-58
DTC: 0183 DTC: 0183
FT (fuel temperature) Sensor Abnormality (abnormally high voltage) FT (fuel temperature) Sensor Abnormality (abnormally high voltage)

Problem symptoms Nothing in particular Problem symptoms Nothing in particular

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check

Yes Yes

Step 2 No Step 2 No
Step 3 Go to step 15. Step 3 Go to step 15.
Use the scan tool to check the FT sensor value. Do you have a scan tool (KW communication)? Use the scan tool to check the FT sensor value. Do you have a scan tool (KW communication)?
1. Connect the scan tool. 1. Connect the scan tool.
2. Start the engine. Yes 2. Start the engine. Yes
3. Use the scan tool to check the "FT sensor" display. 3. Use the scan tool to check the "FT sensor" display.

Reference value 4.85 V No Reference value 4.85 V No


Is the “FT sensor” value at or above the Go to diagnostic aid. Is the “FT sensor” value at or above the Go to diagnostic aid.
reference value? reference value?
Step 4 Step 4
Check the installation status of the FT sensor, the ECM Yes Check the installation status of the FT sensor, the ECM Yes
and the intermediate connector. and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is No 2. Repair or replace as necessary if a problem is No
detected. Was a problem detected? detected. Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 5 Step 5
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the FT sensor connector. 2. Remove the FT sensor connector.
3. Use a jumper cable to create a short circuit between 3. Use a jumper cable to create a short circuit between
the signal terminal of the FT sensor connector and the the signal terminal of the FT sensor connector and the
GND terminal. No Reference value 0 V GND terminal. No Reference value 0 V
4. Turn the key switch “ON”. Is the “FT sensor” value at or below the 4. Turn the key switch “ON”. Is the “FT sensor” value at or below the
5. Use the scan tool to check the “FT sensor” display. reference value? 5. Use the scan tool to check the “FT sensor” display. reference value?

Yes Yes
Go to step 9. Go to step 9.
Step 6 Step 6
1. Use the breaker box or DMM to inspect whether there 1. Use the breaker box or DMM to inspect whether there
is a short circuit with the power supply circuit or is a short circuit with the power supply circuit or
ignition power supply circuit in the signal circuit ignition power supply circuit in the signal circuit
between the ECM and FT sensor. between the ECM and FT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: Notes:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
Important: No Important: No
If the FT sensor circuit is short-circuited to the power Was a problem detected? If the FT sensor circuit is short-circuited to the power Was a problem detected?
supply circuit, there may be sensors that are damaged. supply circuit, there may be sensors that are damaged.
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 13. Go to step 13.

Step 7 Step 7
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and FT sensor. between the ECM and FT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: No Notes: No
Was a problem detected? Was a problem detected?
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
• Disconnection Yes • Disconnection Yes
• High resistance Go to step 13. • High resistance Go to step 13.
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

Go to step 8. Go to step 8.

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4021-59 4021-59

Step 8 Step 8
1. Use the breaker box or DMM to check whether the From step 7 1. Use the breaker box or DMM to check whether the From step 7
conditions below are present in the GND circuit between the conditions below are present in the GND circuit between the
ECM and FT sensor. ECM and FT sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. sensors on actual machine.
• Disconnection • Disconnection
• High resistance No • High resistance No
Was a problem detected? Was a problem detected?
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Yes Yes

From step 5 From step 5


Step 9 Step 9
Replace the supply pump (FT sensor). Replace the supply pump (FT sensor).

Is the action complete? Is the action complete?

Step 11 Yes Step 11 Yes


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software version is 2. Perform rewriting if updating the ECM software version is
necessary. necessary.
For details on checking the ECM and the rewriting, see “How to For details on checking the ECM and the rewriting, see “How to
Use EMPS”. No Use EMPS”. No
Step 10 Step 10
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 12 Step 12
Replace the ECM. Yes Replace the ECM. Yes
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Step 13 Yes Step 13 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
(See the service support DIAG (trouble diagnosis) screen (See the service support DIAG (trouble diagnosis) screen
for information on deleting diagnostic trouble codes.) No for information on deleting diagnostic trouble codes.) No
3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0183 been 3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0183 been
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 14 Step 14
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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4021-60 4021-60

Step 15 From step 2 Step 15 From step 2


1. Start the engine. 1. Start the engine.
2. Check the “Fuel Temperature” display. 2. Check the “Fuel Temperature” display.
Because backup mode is entered after the trouble Because backup mode is entered after the trouble
judgment, the suction air temperature display is 214 °C. judgment, the suction air temperature display is 214 °C.

Reference value 214 °C (error display value) No Reference value 214 °C (error display value) No
Is the “Fuel Temperature” display showing the error Go to diagnostic aid. Is the “Fuel Temperature” display showing the error Go to diagnostic aid.
display value? display value?
Step 16 Step 16
Check the installation status of the FT sensor, the ECM and the Yes Check the installation status of the FT sensor, the ECM and the Yes
intermediate connector. intermediate connector.
1. Inspect whether there is any backlash or looseness in the 1. Inspect whether there is any backlash or looseness in the
installation of the connectors. installation of the connectors.
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

No No
Was a problem detected? . Was a problem detected? .
Step 17 Step 17
1. Use the breaker box or DMM to inspect whether there is a 1. Use the breaker box or DMM to inspect whether there is a
short circuit with the power supply circuit or ignition power Go to step 13. short circuit with the power supply circuit or ignition power Go to step 13.
supply circuit in the signal circuit between the ECM and FT supply circuit in the signal circuit between the ECM and FT
sensor. sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. sensors on actual machine.
Important: No Important: No
If the FT sensor circuit is short-circuited to the power supply Was a problem detected? If the FT sensor circuit is short-circuited to the power supply Was a problem detected?
circuit, there may be sensors that are damaged. circuit, there may be sensors that are damaged.
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 13. Go to step 13.

Step 18 Step 18
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit between conditions below are present in the signal circuit between
the ECM and FT sensor. No the ECM and FT sensor. No
See the Breaker Box Inspection Procedure. Was a problem detected? See the Breaker Box Inspection Procedure. Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. Yes sensors on actual machine. Yes
• Short circuit with FT sensor GND circuit Go to step 13. • Short circuit with FT sensor GND circuit Go to step 13.
• Short circuit with GND • Short circuit with GND
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

Step 19 Step 19
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the GND circuit between the conditions below are present in the GND circuit between the
ECM and FT sensor. No ECM and FT sensor. No
See the Breaker Box Inspection Procedure. Was a problem detected? See the Breaker Box Inspection Procedure. Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. Yes sensors on actual machine. Yes
• Disconnection Go to step 13. • Disconnection Go to step 13.
• High resistance • High resistance
2. Repair or replace as necessary if a problem is detected. 2. Repair or replace as necessary if a problem is detected.

Go to step 9. Go to step 9.

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4021-61 4021-61
Block diagram Block diagram

OIL PRESS. SENSOR OIL PRESS. SENSOR

WATER TEMP. SENSOR WATER TEMP. SENSOR

FUEL TEMP. SENSOR FUEL TEMP. SENSOR

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Recovery from failure Recovery from failure


3 - 10 min. required for trouble judgment. 3 - 10 min. required for trouble judgment.
Preconditions when DTC is set Preconditions when DTC is set
• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630, 1632 are not detected. • DTC: 1630, 1632 are not detected.
• At least 3 min. passed after engine start. • At least 3 min. passed after engine start.

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4021-62 4021-62
Diagnostic aid Diagnostic aid
• Check that the temperature of the FT sensor and IAT (suction air temperature) sensor are close in value before starting • Check that the temperature of the FT sensor and IAT (suction air temperature) sensor are close in value before starting
when the engine is cool. when the engine is cool.
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Breaker box inspection procedure Breaker box inspection procedure


For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with power 18 V or Short circuit with power 18 V or
6 value mea- connector. 83-GND 0V 6 value mea- connector. 83-GND 0V
supply circuit higher supply circuit higher
surement • Key switch "ON" surement • Key switch "ON"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 83-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 83-Sensor connector 100 Ω or 10 M Ω or
7 measure- connector. 7 measure- connector.
high resistance signal terminal lower higher high resistance signal terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 79-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 79-Sensor connector 100 Ω or 10 M Ω or
8 measure- connector. 8 measure- connector.
high resistance GND terminal lower higher high resistance GND terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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4021-63 4021-63
DTC: 0192 DTC: 0192
Common Rail Pressure Sensor Abnormality (abnormally low voltage) Common Rail Pressure Sensor Abnormality (abnormally low voltage)

Engine rev-up, hunting Engine rev-up, hunting

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check

Yes Yes

Step 3 Step 2 No Step 3 Step 2 No


Use the scan tool to check the common rail pressure Go to step 14. Use the scan tool to check the common rail pressure Go to step 14.
Do you have a scan tool (KW communication)? Do you have a scan tool (KW communication)?
sensor value. sensor value.
1. Connect the scan tool. 1. Connect the scan tool.
2. Start the engine. Yes 2. Start the engine. Yes
3. Use the scan tool to check the “Common rail pressure 3. Use the scan tool to check the “Common rail pressure
sensor” display. sensor” display.

Reference value 0.7 V (during idling) No Reference value 0.7 V (during idling) No
Is the “Common rail pressure sensor” value at or Go to diagnostic aid. Is the “Common rail pressure sensor” value at or Go to diagnostic aid.
below the reference value? below the reference value?
Step 4 Step 4
Check the installation status of the common rail pressure Yes Check the installation status of the common rail pressure Yes
sensor, the ECM and the intermediate connector. sensor, the ECM and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is No 2. Repair or replace as necessary if a problem is No
detected. Was a problem detected? detected. Was a problem detected?

Yes Yes
Go to step 12. Go to step 12.

Step 5 Step 5
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the common rail pressure sensor connector. 2. Remove the common rail pressure sensor connector.
3. Turn the key switch “ON”. 3. Turn the key switch “ON”.
4. Use the scan tool to check the “Common rail pressure No Reference value 0 V 4. Use the scan tool to check the “Common rail pressure No Reference value 0 V
sensor” display. Is the output voltage of the “Common rail sensor” display. Is the output voltage of the “Common rail
pressure sensor” at the reference value? pressure sensor” at the reference value?

Yes Yes
Go to step 8. Go to step 8.
Step 6 Step 6
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the power supply conditions below are present in the power supply
circuit between the ECM and common rail pressure circuit between the ECM and common rail pressure
sensor. sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: Notes:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
• Disconnection No • Disconnection No
• High resistance Was a problem detected? • High resistance Was a problem detected?
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. Yes detected. Yes
Go to step 12. Go to step 12.

Step 7 Step 7
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and common rail pressure sensor. between the ECM and common rail pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: No Notes: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
• Short circuit with common rail pressure sensor GND • Short circuit with common rail pressure sensor GND
circuit Yes circuit Yes
• Short circuit with GND Go to step 12. • Short circuit with GND Go to step 12.
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

Go to step 9. Go to step 9.

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4021-64 4021-64

From step 5 From step 5


Step 8 Step 8
Replace the common rail (common rail pressure sensor). Replace the common rail (common rail pressure sensor).
Note: Note:
See the “Engine” section in the Service Manual for the work See the “Engine” section in the Service Manual for the work
procedures. procedures.
Is the action complete? Is the action complete?

Yes Yes

Step 10 Step 10
1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software version is From step 7 2. Perform rewriting if updating the ECM software version is From step 7
necessary. necessary.
For details on checking the ECM and the rewriting, see “How to For details on checking the ECM and the rewriting, see “How to
Use EMPS”. No Use EMPS”. No
Step 9 Step 9
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 11 Step 11
Replace the ECM. Yes Replace the ECM. Yes
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Step 12 Yes Step 12 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) screen for See the service support DIAG (trouble diagnosis) screen for
information on deleting diagnostic trouble codes. No information on deleting diagnostic trouble codes. No
3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0192 been 3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0192 been
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 13 Step 13
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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4021-65 4021-65

Step 14 From step 2 Step 14 From step 2


Check the installation status of the common rail pressure Check the installation status of the common rail pressure
sensor, the ECM and the intermediate connector. sensor, the ECM and the intermediate connector.
1. Inspect whether there is any backlash or looseness in the 1. Inspect whether there is any backlash or looseness in the
installation of the connectors. installation of the connectors.
2. Repair or replace as necessary if a problem is detected. No 2. Repair or replace as necessary if a problem is detected. No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 12. Go to step 12.
Step 15 Step 15
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the common rail pressure sensor connector. 2. Remove the common rail pressure sensor connector.
3. Turn the key switch “ON”. 3. Turn the key switch “ON”.
4. Connect the DMM between the ground and the signal 4. Connect the DMM between the ground and the signal
terminal of the common rail pressure sensor. No terminal of the common rail pressure sensor. No
Reference value 0 V Reference value 0 V
Is the DMM display at the reference value? Is the DMM display at the reference value?

Yes Yes
Go to step 8. Go to step 8.

Go to step 6. Go to step 6.

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4021-66 4021-66
Block diagram Block diagram

EGR MOTOR EGR MOTOR

EGR POSITION SENSOR EGR POSITION SENSOR

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630, 1632 are not detected. • DTC: 1630, 1632 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-67 4021-67
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 87-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 87-Sensor connector 100 Ω or 10 M Ω or
6 measure- connector. 6 measure- connector.
high resistance signal terminal lower higher high resistance signal terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
82-101 82-101
Resistance • Remove the sensor Resistance • Remove the sensor
Short circuit with GND 90-101 10 M Ω 100 Ω or Short circuit with GND 90-101 10 M Ω 100 Ω or
measure- connector. measure- connector.
circuit/GND 82-GND or higher lower circuit/GND 82-GND or higher lower
ment • Key switch "OFF" ment • Key switch "OFF"
90-GND 90-GND
7 7
82-Sensor connector 82-Sensor connector
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ signal terminal 100 Ω or 10 M Ω or Disconnection/ signal terminal 100 Ω or 10 M Ω or
measure- connector. measure- connector.
high resistance 90-Sensor connector lower higher high resistance 90-Sensor connector lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
signal terminal signal terminal

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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4021-68 4021-68
DTC: 0193 DTC: 0193
Common Rail Pressure Sensor Abnormality (abnormally high voltage) Common Rail Pressure Sensor Abnormality (abnormally high voltage)

Possibilities of output reduction and engine Possibilities of output reduction and engine
stalling stalling

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check

Yes Yes

Step 3 Step 2 No Step 3 Step 2 No


Use the scan tool to check the common rail pressure Go to step 15. Use the scan tool to check the common rail pressure Go to step 15.
Do you have a scan tool (KW communication)? Do you have a scan tool (KW communication)?
sensor value. sensor value.
1. Connect the scan tool. 1. Connect the scan tool.
2. Start the engine. Yes 2. Start the engine. Yes
3. Use the scan tool to check the “Common rail pressure 3. Use the scan tool to check the “Common rail pressure
sensor” display. sensor” display.

Reference value 4.5 V No Reference value 4.5 V No


Is the “Common rail pressure sensor” value at or Go to diagnostic aid. Is the “Common rail pressure sensor” value at or Go to diagnostic aid.
above the reference value? above the reference value?
Step 4 Step 4
Check the installation status of the common rail pressure Yes Check the installation status of the common rail pressure Yes
sensor, the ECM and the intermediate connector. sensor, the ECM and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is No 2. Repair or replace as necessary if a problem is No
detected. Was a problem detected? detected. Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 5 Step 5
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the common rail pressure sensor connector. 2. Remove the common rail pressure sensor connector.
3. Use a jumper cable to create a short circuit between 3. Use a jumper cable to create a short circuit between
the signal terminal of the common rail pressure the signal terminal of the common rail pressure
sensor connector and the signal terminal. No sensor connector and the signal terminal. No
4. Turn the key switch “ON”. Reference value 4.8 V 4. Turn the key switch “ON”. Reference value 4.8 V
5. Use the scan tool to check the “Common rail pressure Is the “Common rail pressure sensor” value at or 5. Use the scan tool to check the “Common rail pressure Is the “Common rail pressure sensor” value at or
sensor” display. below the reference value? sensor” display. below the reference value?

Yes Yes
Go to step 9. Go to step 9.
Step 6 Step 6
1. Use the breaker box or DMM to inspect whether there 1. Use the breaker box or DMM to inspect whether there
is a short circuit with the power supply circuit or is a short circuit with the power supply circuit or
ignition power supply circuit in the signal circuit ignition power supply circuit in the signal circuit
between the ECM and common rail pressure sensor. between the ECM and common rail pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: Notes:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
Important: No Important: No
If the common rail pressure sensor circuit is short- Was a problem detected? If the common rail pressure sensor circuit is short- Was a problem detected?
circuited to the power supply circuit, there may be circuited to the power supply circuit, there may be
sensors that are damaged. sensors that are damaged.
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 13. Go to step 13.

Step 7 Step 7
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and common rail pressure sensor. between the ECM and common rail pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: No Notes: No
Was a problem detected? Was a problem detected?
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
• Disconnection Yes • Disconnection Yes
• High resistance Go to step 13. • High resistance Go to step 13.
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

Go to step 8. Go to step 8.

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4021-69 4021-69

Step 8 From step 7 Step 8 From step 7


1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the GND circuit conditions below are present in the GND circuit
between the ECM and common rail pressure sensor. between the ECM and common rail pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: No Notes: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
2. Repair or replace as necessary if a problem is Go to step 13. 2. Repair or replace as necessary if a problem is Go to step 13.
detected. detected.

From step 5 From step 5

Step 9 Step 9
Replace the common rail (common rail pressure sensor). Replace the common rail (common rail pressure sensor).
Note: Note:
See the “Engine” section in the Service Manual for the See the “Engine” section in the Service Manual for the
work procedures. work procedures.
Is the action complete? Is the action complete?

Yes Yes
Go to step 13. Go to step 13.
Step 11 Step 11
1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. No version is necessary. No
For details on checking the ECM and the rewriting, see Step 10 For details on checking the ECM and the rewriting, see Step 10
“How to Use EMPS”. Is there an EMPS? “How to Use EMPS”. Is there an EMPS?
Notes: Notes:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. Yes perform EGR learning. Yes
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. Is the action complete? 2. Turn the key switch “OFF”. Is the action complete?
3. Wait about 10 sec. 3. Wait about 10 sec.

Yes Yes
Go to step 13. Go to step 13.
Step 12 Step 12
Replace the ECM. Replace the ECM.
Notes: Notes:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. Is the action complete? 1. Turn the key switch “ON”. Is the action complete?
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 13 Step 13
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. (See the service 2. Delete the diagnostic trouble code. (See the service
support DIAG (trouble diagnosis) screen for No Has a diagnostic trouble code: 0193 been support DIAG (trouble diagnosis) screen for No Has a diagnostic trouble code: 0193 been
information on deleting diagnostic trouble codes.) detected? information on deleting diagnostic trouble codes.) detected?
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when Yes 4. Perform a test drive under the “Preconditions when Yes
diagnostic trouble code is set”. Go to step 2. diagnostic trouble code is set”. Go to step 2.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 14 Step 14
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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4021-70 4021-70

Step 15 From step 2 Step 15 From step 2


Check the installation status of the common rail pressure Check the installation status of the common rail pressure
sensor, the ECM and the intermediate connector. sensor, the ECM and the intermediate connector.
1. Inspect whether there is any backlash or looseness in the 1. Inspect whether there is any backlash or looseness in the
installation of the connectors. installation of the connectors.
2. Repair or replace as necessary if a problem is detected. No 2. Repair or replace as necessary if a problem is detected. No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 16 Step 16
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the common rail pressure sensor connector. 2. Remove the common rail pressure sensor connector.
3. Turn the key switch “ON”. 3. Turn the key switch “ON”.
4. Connect the DMM between the signal terminal and the 4. Connect the DMM between the signal terminal and the
power supply terminal of the common rail pressure sensor. No Reference value 4.8 V power supply terminal of the common rail pressure sensor. No Reference value 4.8 V
Is the DMM display at or below the reference Is the DMM display at or below the reference
value? value?

Yes Yes
Go to step 9. Go to step 9.

Go to step 6. Go to step 6.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-71 4021-71
Block diagram Block diagram

EGR MOTOR EGR MOTOR

EGR POSITION SENSOR EGR POSITION SENSOR

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630, 1635 are not detected. • DTC: 1630, 1635 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-72 4021-72
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value

Voltage • Remove the sensor Voltage • Remove the sensor


Short circuit with power 82-GND 18 V or Short circuit with power 82-GND 18 V or
6 value mea- connector. 0V 6 value mea- connector. 0V
supply circuit 90-GND higher supply circuit 90-GND higher
surement • Key switch "ON" surement • Key switch "ON"
87-Sensor connector 87-Sensor connector
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ signal terminal 100 Ω or 10 M Ω or Disconnection/ signal terminal 100 Ω or 10 M Ω or
7 measure- connector. 7 measure- connector.
high resistance 90-Sensor connector lower higher high resistance 90-Sensor connector lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
signal terminal signal terminal
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 101-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 101-Sensor connector 100 Ω or 10 M Ω or
8 measure- connector. 8 measure- connector.
high resistance GND terminal lower higher high resistance GND terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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4021-73 4021-73
DTC: 0201 DTC: 0201
No. 1 Cylinder Injector Drive System Disconnection No. 1 Cylinder Injector Drive System Disconnection

High engine vibration, unstable idling speed, output reduction, High engine vibration, unstable idling speed, output reduction,
revolution problem revolution problem

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check
Step 2 Step 2
Confirm the diagnostic trouble code. Yes Confirm the diagnostic trouble code. Yes
1. Turn the key switch “OFF” for at least 10 sec. 1. Turn the key switch “OFF” for at least 10 sec.
2. Start the engine. 2. Start the engine.
3. Confirm the diagnostic trouble code. 3. Confirm the diagnostic trouble code.

Step 3 No Step 3 No
1. Turn the key switch “OFF”. Has a diagnostic trouble code been detected? Go to diagnostic aid. 1. Turn the key switch “OFF”. Has a diagnostic trouble code been detected? Go to diagnostic aid.
2. Remove the intermediate connector (fan side H-94) 2. Remove the intermediate connector (fan side H-94)
from the cylinder head cover case. from the cylinder head cover case.
Yes Yes
3. Measure the resistance between the terminals of the 3. Measure the resistance between the terminals of the
intermediate connector (between the power supply intermediate connector (between the power supply
terminal and the No. 1 cylinder injector drive signal terminal and the No. 1 cylinder injector drive signal
terminal). terminal).

No Reference value 0.45 ± 0.1 Ω (20 °C) No Reference value 0.45 ± 0.1 Ω (20 °C)
Is the resistance at or below the reference Is the resistance at or below the reference
Step 4 value? Step 4 value?
1. Use the breaker box or DMM to inspect whether the 1. Use the breaker box or DMM to inspect whether the
conditions below are present in the circuit between Yes conditions below are present in the circuit between Yes
the ECM and intermediate connector (CN.A3). the ECM and intermediate connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures No If there is no breaker box, see the Inspection procedures No
Was a problem detected? Go to step 8. Was a problem detected? Go to step 8.
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
2. Repair or replace as necessary if a problem is Go to step 13. 2. Repair or replace as necessary if a problem is Go to step 13.
detected. detected.

Step 5 Step 5
Check the installation of the injector terminal nut. Check the installation of the injector terminal nut.
1. Remove the cylinder head cover. 1. Remove the cylinder head cover.
2. Check for looseness in the injector terminal nut. 2. Check for looseness in the injector terminal nut.
3. Repair as necessary if a problem is detected. 3. Repair as necessary if a problem is detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 6 Step 6
Check the installation of the intermediate connector. Check the installation of the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 7 Step 7
1. Inspect whether the conditions below are present in 1. Inspect whether the conditions below are present in
the circuit between the injector terminal and the circuit between the injector terminal and
intermediate connector. intermediate connector.
• Disconnection • Disconnection
• High resistance No • High resistance No
2. Repair or replace as necessary if a problem is Is there a problem in the circuit? 2. Repair or replace as necessary if a problem is Is there a problem in the circuit?
detected. detected.

Yes Yes
Go to step 13. Go to step 13.

Go to step 9. Go to step 9.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-74 4021-74

Step 8 Step 8
Check the installation of the ECM connector. From step 4 Check the installation of the ECM connector. From step 4
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the ECM. 2. Remove the ECM.
3. Inspect whether there is any backlash or looseness in the 3. Inspect whether there is any backlash or looseness in the
installation of the connectors. installation of the connectors.
4. Repair as necessary if a problem is detected. 4. Repair as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?

Yes Yes
Step 9 Step 9
1. Replace the No. 1 cylinder injector. 1. Replace the No. 1 cylinder injector.
Note: From step 7 Note: From step 7
See the “Engine” section in the Service Manual for the work See the “Engine” section in the Service Manual for the work
procedures. procedures.

Is the action complete? Is the action complete?

Step 11 Yes Step 11 Yes


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software version is 2. Perform rewriting if updating the ECM software version is
necessary. necessary.
For details on checking the ECM and the rewriting, see “How to For details on checking the ECM and the rewriting, see “How to
Use EMPS”. No Use EMPS”. No
Step 10 Step 10
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 12 Step 12
Replace the ECM. Yes Replace the ECM. Yes
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Step 13 Yes Step 13 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) screen for See the service support DIAG (trouble diagnosis) screen for
information on deleting diagnostic trouble codes. No information on deleting diagnostic trouble codes. No
3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0201 been 3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0201 been
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 14 Step 14
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-75 4021-75
Block diagram Block diagram

CYLINDER #1 CYLINDER #1

CYLINDER #4 CYLINDER #4

CYLINDER #2 CYLINDER #2

CYLINDER #3 CYLINDER #3

65*- 65*-

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4021-76 4021-76
Cylinder No. and injection sequence Cylinder No. and injection sequence

Name Name
1. 1st cylinder 1. 1st cylinder
2. 2nd cylinder 2. 2nd cylinder
3. 3rd cylinder 3. 3rd cylinder
4. 4th cylinder 4. 4th cylinder
5. Cylinder block 5. Cylinder block
6. Engine front side 6. Engine front side

Injection sequence: 1 → 3 → 4 → 2 Injection sequence: 1 → 3 → 4 → 2


Preconditions when DTC is set Preconditions when DTC is set
• Main relay power supply voltage is 18 V or higher. • Main relay power supply voltage is 18 V or higher.
• At least 70 min-1 • At least 70 min-1
• DTC: 0611, 1261 are not detected. • DTC: 0611, 1261 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-77 4021-77
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance • Remove the intermedi- 119-Intermediate Resistance • Remove the intermedi- 119-Intermediate
Disconnection/
ate connector. 100 Ω or 10 M Ω or Disconnection/
ate connector. 100 Ω or 10 M Ω or
4 measure- connector terminal 4 measure- connector terminal
high resistance lower higher high resistance lower higher
ment • Key switch "OFF" (CN. A3 No. 5) ment • Key switch "OFF" (CN. A3 No. 5)

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-78 4021-78
DTC: 0202 DTC: 0202
No. 2 Cylinder Injector Drive System Disconnection No. 2 Cylinder Injector Drive System Disconnection

High engine vibration, unstable idling speed, output reduction, High engine vibration, unstable idling speed, output reduction,
revolution problem revolution problem

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check
Step 2 Step 2
Confirm the diagnostic trouble code. Yes Confirm the diagnostic trouble code. Yes
1. Turn the key switch “OFF” for at least 10 sec. 1. Turn the key switch “OFF” for at least 10 sec.
2. Start the engine. 2. Start the engine.
3. Confirm the diagnostic trouble code. 3. Confirm the diagnostic trouble code.

Step 3 No Step 3 No
1. Turn the key switch “OFF”. Has a diagnostic trouble code been detected? Go to diagnostic aid. 1. Turn the key switch “OFF”. Has a diagnostic trouble code been detected? Go to diagnostic aid.
2. Remove the intermediate connector (fan side H-94) 2. Remove the intermediate connector (fan side H-94)
from the cylinder head cover case. from the cylinder head cover case.
Yes Yes
3. Measure the resistance between the terminals of the 3. Measure the resistance between the terminals of the
intermediate connector (between the power supply intermediate connector (between the power supply
terminal and the No. 2 cylinder injector drive signal terminal and the No. 2 cylinder injector drive signal
terminal). terminal).

No Reference value 4.5 ± 0.1 Ω (20 °C) No Reference value 4.5 ± 0.1 Ω (20 °C)
Is the resistance at or below the reference Is the resistance at or below the reference
Step 4 value? Step 4 value?
1. Use the breaker box or DMM to inspect whether the 1. Use the breaker box or DMM to inspect whether the
conditions below are present in the circuit between Yes conditions below are present in the circuit between Yes
the ECM and intermediate connector (CN.A3). the ECM and intermediate connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures No If there is no breaker box, see the Inspection procedures No
Was a problem detected? Go to step 8. Was a problem detected? Go to step 8.
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
2. Repair or replace as necessary if a problem is Go to step 13. 2. Repair or replace as necessary if a problem is Go to step 13.
detected. detected.

Step 5 Step 5
Check the installation of the injector terminal nut. Check the installation of the injector terminal nut.
1. Remove the cylinder head cover. 1. Remove the cylinder head cover.
2. Check for looseness in the injector terminal nut. 2. Check for looseness in the injector terminal nut.
3. Repair as necessary if a problem is detected. 3. Repair as necessary if a problem is detected.
No Step 5 No Step 5
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 6 Step 6
Check the installation of the intermediate connector. Check the installation of the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 7 Step 7
1. Inspect whether the conditions below are present in 1. Inspect whether the conditions below are present in
the circuit between the injector terminal and the circuit between the injector terminal and
intermediate connector. intermediate connector.
• Disconnection • Disconnection
• High resistance No • High resistance No
2. Repair or replace as necessary if a problem is Is there a problem in the circuit? 2. Repair or replace as necessary if a problem is Is there a problem in the circuit?
detected. detected.

Yes Yes
Go to step 13. Go to step 13.

Go to step 9. Go to step 9.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-79 4021-79

Step 8 Step 8
Check the installation of the ECM connector. From step 4 Check the installation of the ECM connector. From step 4
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the ECM. 2. Remove the ECM.
3. Inspect whether there is any backlash or looseness in the 3. Inspect whether there is any backlash or looseness in the
installation of the connectors. installation of the connectors.
4. Repair as necessary if a problem is detected. 4. Repair as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?

Yes Yes
Step 9 Step 9
1. Replace the No. 2 cylinder injector. 1. Replace the No. 2 cylinder injector.
Note: From step 7 Note: From step 7
See the “Engine” section in the Service Manual for the work See the “Engine” section in the Service Manual for the work
procedures. procedures.

Is the action complete? Is the action complete?

Step 11 Yes Step 11 Yes


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software version is 2. Perform rewriting if updating the ECM software version is
necessary. necessary.
For details on checking the ECM and the rewriting, see “How to For details on checking the ECM and the rewriting, see “How to
Use EMPS”. No Use EMPS”. No
Step 10 Step 10
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 12 Step 12
Replace the ECM. Yes Replace the ECM. Yes
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Step 13 Yes Step 13 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) screen for See the service support DIAG (trouble diagnosis) screen for
information on deleting diagnostic trouble codes. No information on deleting diagnostic trouble codes. No
3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0202 been 3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0202 been
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 14 Step 14
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-80 4021-80
Block diagram Block diagram

CYLINDER #1 CYLINDER #1

CYLINDER #4 CYLINDER #4

CYLINDER #2 CYLINDER #2

CYLINDER #3 CYLINDER #3

65*- 65*-

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-81 4021-81
Cylinder No. and injection sequence Cylinder No. and injection sequence

Name Name
1. 1st cylinder 1. 1st cylinder
2. 2nd cylinder 2. 2nd cylinder
3. 3rd cylinder 3. 3rd cylinder
4. 4th cylinder 4. 4th cylinder
5. Cylinder block 5. Cylinder block
6. Engine front 6. Engine front

Injection sequence: 1 → 3 → 4 → 2 Injection sequence: 1 → 3 → 4 → 2


Preconditions when DTC is set Preconditions when DTC is set
• Main relay power supply voltage is 18 V or higher. • Main relay power supply voltage is 18 V or higher.
• At least 70 min-1 • At least 70 min-1
• DTC: 0612, 1262 are not detected. • DTC: 0612, 1262 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-82 4021-82
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance • Remove the intermedi- 18-Intermediate Resistance • Remove the intermedi- 18-Intermediate
Disconnection/h
ate connector. 100 Ω or 10 M Ω or Disconnection/h
ate connector. 100 Ω or 10 M Ω or
4 measure- connector terminal 4 measure- connector terminal
igh resistance lower higher igh resistance lower higher
ment • Key switch "OFF" (CN. A3 No. 6) ment • Key switch "OFF" (CN. A3 No. 6)

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-83 4021-83
DTC: 0203 DTC: 0203
No. 3 Cylinder Injector Drive System Disconnection No. 3 Cylinder Injector Drive System Disconnection

High engine vibration, unstable idling speed, output reduction, High engine vibration, unstable idling speed, output reduction,
revolution problem revolution problem

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check
Step 2 Step 2
Confirm the diagnostic trouble code. Yes Confirm the diagnostic trouble code. Yes
1. Turn the key switch “OFF” for at least 10 sec. 1. Turn the key switch “OFF” for at least 10 sec.
2. Start the engine. 2. Start the engine.
3. Confirm the diagnostic trouble code. 3. Confirm the diagnostic trouble code.

Step 3 No Step 3 No
1. Turn the key switch “OFF”. Has a diagnostic trouble code been detected? Go to diagnostic aid. 1. Turn the key switch “OFF”. Has a diagnostic trouble code been detected? Go to diagnostic aid.
2. Remove the intermediate connector (CN.A3) from the 2. Remove the intermediate connector (CN.A3) from the
cylinder head cover case. cylinder head cover case.
Yes Yes
3. Measure the resistance between the terminals of the 3. Measure the resistance between the terminals of the
intermediate connector (between the power supply intermediate connector (between the power supply
terminal and the No. 3 cylinder injector drive signal terminal and the No. 3 cylinder injector drive signal
terminal). terminal).

No Reference value 0.45 ± 0.1 Ω (20 °C) No Reference value 0.45 ± 0.1 Ω (20 °C)
Is the resistance at or below the reference Is the resistance at or below the reference
Step 4 value? Step 4 value?
1. Use the breaker box or DMM to inspect whether the 1. Use the breaker box or DMM to inspect whether the
conditions below are present in the circuit between Yes conditions below are present in the circuit between Yes
the ECM and intermediate connector (CN.A3). the ECM and intermediate connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures No If there is no breaker box, see the Inspection procedures No
Was a problem detected? Go to step 8. Was a problem detected? Go to step 8.
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
2. Repair or replace as necessary if a problem is Go to step 13. 2. Repair or replace as necessary if a problem is Go to step 13.
detected. detected.

Step 5 Step 5
Check the installation of the injector terminal nut. Check the installation of the injector terminal nut.
1. Remove the cylinder head cover. 1. Remove the cylinder head cover.
2. Check for looseness in the injector terminal nut. 2. Check for looseness in the injector terminal nut.
3. Repair as necessary if a problem is detected. 3. Repair as necessary if a problem is detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 6 Step 6
Check the installation of the intermediate connector. Check the installation of the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 7 Step 7
1. Inspect whether the conditions below are present in 1. Inspect whether the conditions below are present in
the circuit between the injector terminal and the circuit between the injector terminal and
intermediate connector. intermediate connector.
• Disconnection • Disconnection
• High resistance No • High resistance No
2. Repair or replace as necessary if a problem is Is there a problem in the circuit? 2. Repair or replace as necessary if a problem is Is there a problem in the circuit?
detected. detected.

Yes Yes
Go to step 13. Go to step 13.

Go to step 9. Go to step 9.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-84 4021-84

Step 8 Step 8
Check the installation of the ECM connector. From step 4 Check the installation of the ECM connector. From step 4
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the ECM. 2. Remove the ECM.
3. Inspect whether there is any backlash or looseness in the 3. Inspect whether there is any backlash or looseness in the
installation of the connectors. installation of the connectors.
4. Repair as necessary if a problem is detected. 4. Repair as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?

Yes Yes
Step 9 Step 9
1. Replace the No. 3 cylinder injector. 1. Replace the No. 3 cylinder injector.
Note: From step 7 Note: From step 7
See the “Engine” section in the Service Manual for the work See the “Engine” section in the Service Manual for the work
procedures. procedures.

Is the action complete? Is the action complete?

Step 11 Yes Step 11 Yes


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software version is 2. Perform rewriting if updating the ECM software version is
necessary. necessary.
For details on checking the ECM and the rewriting, see “How to For details on checking the ECM and the rewriting, see “How to
Use EMPS”. No Use EMPS”. No
Step 10 Step 10
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 12 Step 12
Replace the ECM. Yes Replace the ECM. Yes
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Step 13 Yes Step 13 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) screen for See the service support DIAG (trouble diagnosis) screen for
information on deleting diagnostic trouble codes. No information on deleting diagnostic trouble codes. No
3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0203 been 3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0203 been
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 14 Step 14
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-85 4021-85
Block diagram Block diagram

CYLINDER #1 CYLINDER #1

CYLINDER #4 CYLINDER #4

CYLINDER #2 CYLINDER #2

CYLINDER #3 CYLINDER #3

65*- 65*-

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-86 4021-86
Cylinder No. and injection sequence Cylinder No. and injection sequence

Name Name
1. 1st cylinder 1. 1st cylinder
2. 2nd cylinder 2. 2nd cylinder
3. 3rd cylinder 3. 3rd cylinder
4. 4th cylinder 4. 4th cylinder
5. Cylinder block 5. Cylinder block
6. Engine front side 6. Engine front side

Injection sequence: 1 → 3 → 4 → 2 Injection sequence: 1 → 3 → 4 → 2


Preconditions when DTC is set Preconditions when DTC is set
• Main relay power supply voltage is 18 V or higher. • Main relay power supply voltage is 18 V or higher.
• 70 min-1 • 70 min-1
• DTC: 0612, 1262 are not detected. • DTC: 0612, 1262 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-87 4021-87
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance • Remove the intermedi- 120-Intermediate Resistance • Remove the intermedi- 120-Intermediate
Disconnection/
ate connector. 100 Ω or 10 M Ω or Disconnection/
ate connector. 100 Ω or 10 M Ω or
4 measure- connector terminal 4 measure- connector terminal
high resistance lower higher high resistance lower higher
ment • Key switch "OFF" (CN. A3 No. 7) ment • Key switch "OFF" (CN. A3 No. 7)

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-88 4021-88
DTC: 0204 DTC: 0204
No. 4 Cylinder Injector Drive System Disconnection No. 4 Cylinder Injector Drive System Disconnection

High engine vibration, unstable idling speed, output reduction, High engine vibration, unstable idling speed, output reduction,
revolution problem revolution problem

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check
Step 2 Step 2
Confirm the diagnostic trouble code. Yes Confirm the diagnostic trouble code. Yes
1. Turn the key switch “OFF” for at least 10 sec. 1. Turn the key switch “OFF” for at least 10 sec.
2. Start the engine. 2. Start the engine.
3. Confirm the diagnostic trouble code. 3. Confirm the diagnostic trouble code.

Step 3 No Step 3 No
1. Turn the key switch “OFF”. Has a diagnostic trouble code been detected? Go to diagnostic aid. 1. Turn the key switch “OFF”. Has a diagnostic trouble code been detected? Go to diagnostic aid.
2. Remove the intermediate connector (CN.A3) from the 2. Remove the intermediate connector (CN.A3) from the
cylinder head cover case. cylinder head cover case.
Yes Yes
3. Measure the resistance between the terminals of the 3. Measure the resistance between the terminals of the
intermediate connector (between the power supply intermediate connector (between the power supply
terminal and the No. 4 cylinder injector drive signal terminal and the No. 4 cylinder injector drive signal
terminal). terminal).

No Reference value 0.45 ± 0.1 Ω (20 °C) No Reference value 0.45 ± 0.1 Ω (20 °C)
Is the resistance at or below the reference Is the resistance at or below the reference
Step 4 value? Step 4 value?
1. Use the breaker box or DMM to inspect whether the 1. Use the breaker box or DMM to inspect whether the
conditions below are present in the circuit between Yes conditions below are present in the circuit between Yes
the ECM and intermediate connector (CN.A3). the ECM and intermediate connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures No If there is no breaker box, see the Inspection procedures No
Was a problem detected? Go to step 8. Was a problem detected? Go to step 8.
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
2. Repair or replace as necessary if a problem is Go to step 13. 2. Repair or replace as necessary if a problem is Go to step 13.
detected. detected.

Step 5 Step 5
Check the installation of the injector terminal nut. Check the installation of the injector terminal nut.
1. Remove the cylinder head cover. 1. Remove the cylinder head cover.
2. Check for looseness in the injector terminal nut. 2. Check for looseness in the injector terminal nut.
3. Repair as necessary if a problem is detected. 3. Repair as necessary if a problem is detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 6 Step 6
Check the installation of the intermediate connector. Check the installation of the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
No No
Has a problem detected? Has a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 7 Step 7
1. Inspect whether the conditions below are present in 1. Inspect whether the conditions below are present in
the circuit between the injector terminal and the circuit between the injector terminal and
intermediate connector. intermediate connector.
• Disconnection • Disconnection
• High resistance No • High resistance No
2. Repair or replace as necessary if a problem is Is there a problem in the circuit? 2. Repair or replace as necessary if a problem is Is there a problem in the circuit?
detected. detected.

Yes Yes
Go to step 13. Go to step 13.

Go to step 9. Go to step 9.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-89 4021-89

Step 8 Step 8
Check the installation of the ECM connector. From step 4 Check the installation of the ECM connector. From step 4
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the ECM. 2. Remove the ECM.
3. Inspect whether there is any backlash or looseness in the 3. Inspect whether there is any backlash or looseness in the
installation of the connectors. installation of the connectors.
4. Repair as necessary if a problem is detected. 4. Repair as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?

Yes Yes
Step 9 Step 9
1. Replace the No. 4 cylinder injector. 1. Replace the No. 4 cylinder injector.
Note: From step 7 Note: From step 7
See the “Engine” section in the Service Manual for the work See the “Engine” section in the Service Manual for the work
procedures. procedures.

Is the action complete? Is the action complete?

Step 11 Yes Step 11 Yes


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software version is 2. Perform rewriting if updating the ECM software version is
necessary. necessary.
For details on checking the ECM and the rewriting, see “How to For details on checking the ECM and the rewriting, see “How to
Use EMPS”. No Use EMPS”. No
Step 10 Step 10
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 12 Step 12
Replace the ECM. Yes Replace the ECM. Yes
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Step 13 Yes Step 13 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) screen for See the service support DIAG (trouble diagnosis) screen for
information on deleting diagnostic trouble codes. No information on deleting diagnostic trouble codes. No
3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0204 been 3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0204 been
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 14 Step 14
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-90 4021-90
Block diagram Block diagram

CYLINDER #1 CYLINDER #1

CYLINDER #4 CYLINDER #4

CYLINDER #2 CYLINDER #2

CYLINDER #3 CYLINDER #3

65*- 65*-

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-91 4021-91
Cylinder No. and injection sequence Cylinder No. and injection sequence

Name Name
1. 1st cylinder 1. 1st cylinder
2. 2nd cylinder 2. 2nd cylinder
3. 3rd cylinder 3. 3rd cylinder
4. 4th cylinder 4. 4th cylinder
5. Cylinder block 5. Cylinder block
6. Engine front side 6. Engine front side

Injection sequence: 1 → 3 → 4 → 2 Injection sequence: 1 → 3 → 4 → 2


Preconditions when DTC is set Preconditions when DTC is set
• Main relay power supply voltage is 18 V or higher. • Main relay power supply voltage is 18 V or higher.
• 70 min-1 • 70 min-1
• DTC: 0611, 1261 are not detected. • DTC: 0611, 1261 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-92 4021-92
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance • Remove the intermedi- 115-Intermediate Resistance • Remove the intermedi- 115-Intermediate
Disconnection/
ate connector. 100 Ω or 10 M Ω or Disconnection/
ate connector. 100 Ω or 10 M Ω or
4 measure- connector terminal 4 measure- connector terminal
high resistance lower higher high resistance lower higher
ment • Key switch "OFF" (CN. A3 No. 8) ment • Key switch "OFF" (CN. A3 No. 8)

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-93 4021-93
DTC: 0219 DTC: 0219
Overrun Overrun

Output reduction Output reduction

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check
Step 2 Step 2
Check the operating conditions (whether or not there was Yes Check the operating conditions (whether or not there was Yes
an operating mistake that caused the excessive engine an operating mistake that caused the excessive engine
speed). (Ask the operator about past operating speed). (Ask the operator about past operating
conditions.) conditions.)

No No
Were there any operating mistakes? Were there any operating mistakes?
Step 3 Step 3
Communicate to the operator that the excessive speed Communicate to the operator that the excessive speed
was caused by an operating mistake, and give operation was caused by an operating mistake, and give operation
guidance. Yes guidance. Yes

Is the action complete? Is the action complete?


Step 4 Step 4
Inspect whether there are any effects (abnormalities in Yes Inspect whether there are any effects (abnormalities in Yes
the engine main unit) due to excessive engine speed, and the engine main unit) due to excessive engine speed, and
perform repair or replacement if any abnormalities are perform repair or replacement if any abnormalities are
found. found.

Is the action complete? Is the action complete?


Step 5 Step 5
Recheck the diagnostic trouble code. Yes Recheck the diagnostic trouble code. Yes
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble No screen for information on deleting diagnostic trouble No
codes. Was a diagnostic trouble code detected? Check repair. codes. Was a diagnostic trouble code detected? Check repair.
3. Turn the key switch "OFF" for at least 10 sec. 3. Turn the key switch "OFF" for at least 10 sec.
4. Perform a test drive under the "Preconditions when 4. Perform a test drive under the "Preconditions when
diagnostic trouble code is set". Yes diagnostic trouble code is set". Yes
5. Confirm the diagnostic trouble code. Go to diagnosis for each diagnostic trouble code. 5. Confirm the diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-94 4021-94
Block diagram Block diagram

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
Diagnostic aid Diagnostic aid
• Load (hydraulic pump etc.) is light. • Load (hydraulic pump etc.) is light.
• CKP (crankshaft position) sensor, CMP (camshaft position) sensor abnormality (signal abnormality) • CKP (crankshaft position) sensor, CMP (camshaft position) sensor abnormality (signal abnormality)
• Engine main unit abnormality (supply pump, injector, main unit abnormality etc.) • Engine main unit abnormality (supply pump, injector, main unit abnormality etc.)
• ECM internal trouble • ECM internal trouble
• Perform inspection to check whether there are any connector connection problems, abnormalities involving friction or break- • Perform inspection to check whether there are any connector connection problems, abnormalities involving friction or break-
ing in harnesses, and whether any wires inside harnesses are touching another circuit and causing a short. Also, perform ing in harnesses, and whether any wires inside harnesses are touching another circuit and causing a short. Also, perform
function diagnosis inspection, check operations and control in each area, and repair any abnormalities. function diagnosis inspection, check operations and control in each area, and repair any abnormalities.
• When this DTC is detected, check for trouble in the engine main unit (seizing or damage). • When this DTC is detected, check for trouble in the engine main unit (seizing or damage).

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-95 4021-95
DTC: 0237 DTC: 0237
Boost Pressure Sensor Abnormality (abnormally low voltage) Boost Pressure Sensor Abnormality (abnormally low voltage)

Possible impact on machine operability Possible impact on machine operability

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check

Step 2 Yes Step 2 Yes


1. Start the engine. 1. Start the engine.
2. Check the boost pressure sensor display. 2. Check the boost pressure sensor display.

Reference value No Reference value No


508 MPa Go to diagnostic aid. 508 MPa Go to diagnostic aid.
(error display value) (error display value)
Is the boost pressure sensor display Is the boost pressure sensor display
showing the error display value? showing the error display value?

Yes Yes

Go to step 3. Go to step 3.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-96 4021-96

Step 3 From step 2 Step 3 From step 2


Check the installation status of the boost pressure sensor Check the installation status of the boost pressure sensor
connector, the ECM and the intermediate connector. connector, the ECM and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Correct as necessary if a problem is detected. No 2. Correct as necessary if a problem is detected. No
Was a problem detected? Was a problem detected?

Step 4 Yes Step 4 Yes


1. Use the breaker box or DMM to inspect whether the 1. Use the breaker box or DMM to inspect whether the
conditions below are present in the power supply conditions below are present in the power supply
circuit between the ECM and boost pressure sensor. circuit between the ECM and boost pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. No for sensors on actual machine. No
• Disconnection Was a problem detected? • Disconnection Was a problem detected?
• High resistance • High resistance
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes

Step 5 Step 5
1. Use the breaker box or DMM to inspect whether the 1. Use the breaker box or DMM to inspect whether the
conditions below are present in the power supply conditions below are present in the power supply
circuit between the ECM and boost pressure sensor. circuit between the ECM and boost pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
• Short circuit with boost pressure sensor GND circuit • Short circuit with boost pressure sensor GND circuit
• Short circuit with GND • Short circuit with GND
• Disconnection • Disconnection
No No
• High resistance Was a problem detected? • High resistance Was a problem detected?
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Yes Yes

Step 6 Step 6
Replace the boost pressure sensor. Replace the boost pressure sensor.

Is the action complete? Is the action complete?


Step 7 Step 7
Recheck the diagnostic trouble code. Yes Recheck the diagnostic trouble code. Yes
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
3. Turn the key switch “OFF” for at least 10 sec. No Has a diagnostic trouble code: 0237 been 3. Turn the key switch “OFF” for at least 10 sec. No Has a diagnostic trouble code: 0237 been
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 8 Step 8
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.
Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-97 4021-97
Block diagram Block diagram

BOOST PRESS. SENSOR BOOST PRESS. SENSOR

BOOST TEMP. SENSOR BOOST TEMP. SENSOR

659) 659)

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630, 1634 are not detected. • DTC: 1630, 1634 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-98 4021-98
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 95-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 95-Sensor connector 100 Ω or 10 M Ω or
6 measure- connector. 6 measure- connector.
high resistance signal terminal lower higher high resistance signal terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
Resistance • Remove the sensor Resistance • Remove the sensor
Short circuit with GND 91-109 10 M Ω 100 Ω or Short circuit with GND 91-109 10 M Ω 100 Ω or
measure- connector. measure- connector.
circuit/GND 91-GND or higher lower circuit/GND 91-GND or higher lower
ment • Key switch "OFF" ment • Key switch "OFF"
7 7
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 91-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 91-Sensor connector 100 Ω or 10 M Ω or
measure- connector. measure- connector.
high resistance signal terminal lower higher high resistance signal terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-99 4021-99
DTC: 0238 DTC: 0238
Boost Pressure Sensor Abnormality (abnormally high voltage) Boost Pressure Sensor Abnormality (abnormally high voltage)

Black smoke produced Black smoke produced

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Execution of service support No Execution of service support


Is the action complete? Is the action complete?
check check

Step 2 Yes Step 2 Yes


1. Start the engine. 1. Start the engine.
2. Check the boost pressure sensor display. 2. Check the boost pressure sensor display.

Reference value No Reference value No


508 MPa Go to diagnostic aid. 508 MPa Go to diagnostic aid.
(error display value) (error display value)
Is the boost pressure sensor display Is the boost pressure sensor display
showing the error display value? showing the error display value?

Yes Yes

Go to step 3. Go to step 3.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-100 4021-100

Step 3 From step 2 Step 3 From step 2


Check the installation status of the boost pressure sensor Check the installation status of the boost pressure sensor
connector, the ECM and the intermediate connector. connector, the ECM and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Correct as necessary if a problem is detected. No 2. Correct as necessary if a problem is detected. No
Was a problem detected? Was a problem detected?

Step 4 Yes Step 4 Yes


1. Use the breaker box or DMM to inspect whether the 1. Use the breaker box or DMM to inspect whether the
there is a short circuit with the power supply circuit or there is a short circuit with the power supply circuit or
ignition power supply circuit in the signal sensor. ignition power supply circuit in the signal sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. No for sensors on actual machine. No
Important: Was a problem detected? Important: Was a problem detected?
If the boost pressure sensor circuit is short-circuited to If the boost pressure sensor circuit is short-circuited to
the power supply circuit, there may be sensors that are the power supply circuit, there may be sensors that are
Yes Yes
damaged. damaged.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 5 Step 5
1. Use the breaker box or DMM to inspect whether the 1. Use the breaker box or DMM to inspect whether the
conditions below are present in the GND circuit conditions below are present in the GND circuit
between the ECM and boost pressure sensor. See the between the ECM and boost pressure sensor. See the
Breaker Box Inspection Procedure. Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance • High resistance
2. Repair as necessary if a problem is detected. No 2. Repair as necessary if a problem is detected. No
Was a problem detected? Was a problem detected?

Yes Yes

Step 6 Step 6
Replace the boost pressure sensor. Replace the boost pressure sensor.

Is the action complete? Is the action complete?


Step 7 Step 7
Recheck the diagnostic trouble code. Yes Recheck the diagnostic trouble code. Yes
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
3. Turn the key switch “OFF” for at least 10 sec. No Has a diagnostic trouble code: 0238 been 3. Turn the key switch “OFF” for at least 10 sec. No Has a diagnostic trouble code: 0238 been
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 8 Step 8
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.
Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-101 4021-101
Block diagram Block diagram

BOOST PRESS. SENSOR BOOST PRESS. SENSOR

BOOST TEMP. SENSOR BOOST TEMP. SENSOR

659) 659)

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630, 1634 are not detected. • DTC: 1630, 1634 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Breaker box inspection procedure Breaker box inspection procedure


For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with power 18 V or Short circuit with power 18 V or
6 value mea- connector. 91-GND 0V 6 value mea- connector. 91-GND 0V
supply circuit higher supply circuit higher
surement • Key switch "ON" surement • Key switch "ON"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 109-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 109-Sensor connector 100 Ω or 10 M Ω or
7 measure- connector. 7 measure- connector.
high resistance GND terminal lower higher high resistance GND terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-102 4021-102
DTC: 0335 DTC: 0335
CKP (crank position) Sensor Abnormality (no signal) CKP (crank position) Sensor Abnormality (no signal)

Possibility of drop of output power, white smoke, Possibility of drop of output power, white smoke,
high vibration, and engine stalling high vibration, and engine stalling
(Restart possible when CMP (cam position) sensor is normal) (Restart possible when CMP (cam position) sensor is normal)

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to Service support check. Is the action complete? Go to Service support check.

Step 2 Yes Step 2 Yes


Check the CKP sensor installation status. Check the CKP sensor installation status.
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Visually inspect the sensor installation status for any 2. Visually inspect the sensor installation status for any
backlash or looseness. Is the action complete? backlash or looseness. Is the action complete?
3. Correct as necessary if a problem is detected. 3. Correct as necessary if a problem is detected.

Step 3 Yes Step 3 Yes


Check the installation status of the CKP sensor, the ECM Check the installation status of the CKP sensor, the ECM
and the intermediate connector. and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is Is the action complete? 2. Repair or replace as necessary if a problem is Is the action complete?
detected. detected.

Step 4 Yes Step 4 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Delete the diagnostic trouble code. 1. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble No Has any other diagnostic trouble code been screen for information on deleting diagnostic trouble No Has any other diagnostic trouble code been
codes. detected? codes. detected?
2. Turn the key switch “OFF” for at least 10 sec. 2. Turn the key switch “OFF” for at least 10 sec.
3. Perform a test drive under the "Preconditions when Yes 3. Perform a test drive under the "Preconditions when Yes
diagnostic trouble code is set". Go to step 12. diagnostic trouble code is set". Go to step 12.
4. Confirm the diagnostic trouble code. 4. Confirm the diagnostic trouble code.

Step 5 Step 5
Inspect the CKP sensor main unit. Inspect the CKP sensor main unit.
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the harness from the CKP sensor. No 2. Remove the harness from the CKP sensor. No
Reference value Reference value
3. Measure the resistance at the sensor connector 3. Measure the resistance at the sensor connector
Between terminals: 108.5 - 142.5 Ω Between terminals: 108.5 - 142.5 Ω
terminal. terminal.
Between each terminal and GND: 㺙 Ω (at Between each terminal and GND: 㺙 Ω (at
normal temperature) normal temperature)
Is the resistance within the reference value Is the resistance within the reference value
Step 6 range? Step 6 range?
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
onditions below are present in the circuit between the Yes onditions below are present in the circuit between the Yes
ECM and CKP sensor. See the Breaker Box ECM and CKP sensor. See the Breaker Box
Inspection Procedure. Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
• Short circuit with GND Go to step 11. • Short circuit with GND Go to step 11.
• Short-circuit between terminals • Short-circuit between terminals
• Short circuit with power supply circuit or ignition Go to step 8. • Short circuit with power supply circuit or ignition Go to step 8.
power supply circuit power supply circuit
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 7 Step 7
Replace the CKP sensor. Replace the CKP sensor.

Is the action complete? Is the action complete?

Yes Yes

Go to step 11. Go to step 11.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-103 4021-103

Step 9 From step 6 Step 9 From step 6


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
"How to Use EMPS". No "How to Use EMPS". No
Step 8 Step 8
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] Yes [EGR learning method] Yes
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. No 3. Wait about 10 sec. No
Is the action complete? Is the action complete?

Yes Yes
Step 10 Step 10
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Is the action complete? 3. Wait about 10 sec. Is the action complete?

Step 11 Step 11
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. No 2. Delete the diagnostic trouble code. No
(See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0335 been (See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0335 been
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes.) codes.)
3. Turn the key switch “OFF” for at least 10 sec. Yes 3. Turn the key switch “OFF” for at least 10 sec. Yes
4. Perform a test drive under the “Preconditions when Go to step 2. 4. Perform a test drive under the “Preconditions when Go to step 2.
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 12 Step 12
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-104 4021-104
Block diagram Block diagram

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Recovery from failure Recovery from failure


During trouble judgment, about 10 sec. of cranking is necessary. During trouble judgment, about 10 sec. of cranking is necessary.
Preconditions when DTC is set Preconditions when DTC is set
• CMP sensor signal is normal. • CMP sensor signal is normal.
• DTC: 0335, 0336, 0340, 0341 and 1345 are not detected. • DTC: 0335, 0336, 0340, 0341 and 1345 are not detected.
• Engine running • Engine running
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.
• With CKP sensor abnormalities, a DTC will not be detected unless the crank rotates 14 times. Especially with low rotation • With CKP sensor abnormalities, a DTC will not be detected unless the crank rotates 14 times. Especially with low rotation
such as during idling, the engine will stall before the crank rotates 14 times if there is no CKP signal. Accordingly, because such as during idling, the engine will stall before the crank rotates 14 times if there is no CKP signal. Accordingly, because
no DTC is detected and backup mode is not entered, restarting after engine stalling is possible and specifying the problem no DTC is detected and backup mode is not entered, restarting after engine stalling is possible and specifying the problem
location will be difficult. When there is an engine stalling problem, increase engine rotation to the maximum with no load and location will be difficult. When there is an engine stalling problem, increase engine rotation to the maximum with no load and
inspect whether a CKP sensor problem is detected during 14 rotations of the crank. If a CKP sensor problem is detected at inspect whether a CKP sensor problem is detected during 14 rotations of the crank. If a CKP sensor problem is detected at
the maximum rotation with no load, a DTC will be detected. For intermittent trouble, increase engine rotation to the maximum the maximum rotation with no load, a DTC will be detected. For intermittent trouble, increase engine rotation to the maximum
with no load and inspect whether DTC 0355 is detected. with no load and inspect whether DTC 0355 is detected.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-105 4021-105
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
106-Sensor connector 106-Sensor connector
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ (-) terminal 100 Ω or 10 M Ω or Disconnection/ (-) terminal 100 Ω or 10 M Ω or
measure- connector. measure- connector.
high resistance 107-Sensor connector lower higher high resistance 107-Sensor connector lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
(+) terminal (+) terminal
Resistance • Remove the sensor Resistance • Remove the sensor
106-GND 10 M Ω 100 Ω or 106-GND 10 M Ω 100 Ω or
Short circuit with GND measure- connector. Short circuit with GND measure- connector.
107-GND or higher lower 107-GND or higher lower
6 ment • Key switch "OFF" 6 ment • Key switch "OFF"
Resistance • Remove the sensor Resistance • Remove the sensor
Short-circuit between 10 M Ω 100 Ω or Short-circuit between 10 M Ω 100 Ω or
measure- connector. 106-1707 measure- connector. 106-1707
terminals or higher lower terminals or higher lower
ment • Key switch "OFF" ment • Key switch "OFF"
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with power 106-GND 18 V or Short circuit with power 106-GND 18 V or
value mea- connector. 0V value mea- connector. 0V
supply circuit 107-GND higher supply circuit 107-GND higher
surement • Key switch "ON" surement • Key switch "ON"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-106 4021-106
DTC: 0336 DTC: 0336
CKP (crank position) Sensor Abnormality (signal abnormality) CKP (crank position) Sensor Abnormality (signal abnormality)

Possibility of drop of output power, white smoke, Possibility of drop of output power, white smoke,
high vibration, and engine stalling high vibration, and engine stalling
(Restart possible when CMP (cam position) sensor is normal) (Restart possible when CMP (cam position) sensor is normal)

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to Service support check. Is the action complete? Go to Service support check.

Step 2 Yes Step 2 Yes


Check the CKP sensor installation status. Check the CKP sensor installation status.
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Visually inspect the sensor installation status for any 2. Visually inspect the sensor installation status for any
backlash or looseness. Is the action complete? backlash or looseness. Is the action complete?
3. Correct as necessary if a problem is detected. 3. Correct as necessary if a problem is detected.

Step 3 Yes Step 3 Yes


Check the installation status of the CKP sensor, the ECM Check the installation status of the CKP sensor, the ECM
and the intermediate connector. and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is Is the action complete? 2. Repair or replace as necessary if a problem is Is the action complete?
detected. detected.

Step 4 Yes Step 4 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Delete the diagnostic trouble code. 1. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble No screen for information on deleting diagnostic trouble No
Was a diagnostic trouble code detected? Was a diagnostic trouble code detected?
codes. codes.
2. Turn the key switch “OFF” for at least 10 sec. 2. Turn the key switch “OFF” for at least 10 sec.
3. Perform a test drive under the "Preconditions when Yes 3. Perform a test drive under the "Preconditions when Yes
diagnostic trouble code is set". Go to step 12. diagnostic trouble code is set". Go to step 12.
4. Confirm the diagnostic trouble code. 4. Confirm the diagnostic trouble code.

Step 5 Step 5
1. Use the breaker box or DMM to inspect for a short 1. Use the breaker box or DMM to inspect for a short
with another signal circuit in the CKP sensor circuit. with another signal circuit in the CKP sensor circuit.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
No No
Note: Was a problem detected? Note: Was a problem detected?
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 12. Go to step 12.

Yes Yes
Step 6 Step 6
Inspect the CKP sensor main unit. Inspect the CKP sensor main unit.
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the harness from the CKP sensor. Reference value 2. Remove the harness from the CKP sensor. Reference value
3. Measure the resistance at the sensor connector Between terminals: 108.5 - 142.5 Ω 3. Measure the resistance at the sensor connector Between terminals: 108.5 - 142.5 Ω
terminal. No terminal. No
Between each terminal and GND: 㺙 Ω (at Between each terminal and GND: 㺙 Ω (at
4. Remove the CKP sensor and inspect to make sure normal temperature) 4. Remove the CKP sensor and inspect to make sure normal temperature)
that the there is no scratching or other damage to the Is the resistance within the reference value that the there is no scratching or other damage to the Is the resistance within the reference value
sensor tip. range? sensor tip. range?

Yes Yes
Go to step 8. Go to step 8.

Step 7 Step 7
Replace the CKP sensor. Replace the CKP sensor.

Is the action complete? Is the action complete?

Yes Yes

Go to step 12. Go to step 12.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-107 4021-107

From step 6 From step 6

Step 8 Step 8
1. Visually inspect the flywheel for missing teeth. 1. Visually inspect the flywheel for missing teeth.
2. If a problem was detected, replace. 2. If a problem was detected, replace.

No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 12. Go to step 12.
Step 10 Step 10
1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see No Step 9 For details on checking the ECM and the rewriting, see No Step 9
"Flash Tool (EMPS)". Is there an EMPS? "Flash Tool (EMPS)". Is there an EMPS?
Note: Note:
When ECM replacement or rewriting is performed, Yes When ECM replacement or rewriting is performed, Yes
perform EGR learning. perform EGR learning.
Step 10 Step 10
EGR learning method EGR learning method
1. Turn the key switch “ON”. No 1. Turn the key switch “ON”. No
2. Turn the key switch “OFF”. Is the action complete? 2. Turn the key switch “OFF”. Is the action complete?
3. Wait about 10 sec. 3. Wait about 10 sec.

Yes Yes
Step 11 Step 11
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Is the action complete? 3. Wait about 10 sec. Is the action complete?

Step 12 Step 12
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. No 2. Delete the diagnostic trouble code. No
(See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0336 been (See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0336 been
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes.) codes.)
3. Turn the key switch “OFF” for at least 10 sec. Yes 3. Turn the key switch “OFF” for at least 10 sec. Yes
4. Perform a test drive under the “Preconditions when Go to step 2. 4. Perform a test drive under the “Preconditions when Go to step 2.
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 13 Step 13
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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4021-108 4021-108
Block diagram Block diagram

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Recovery from failure Recovery from failure


During trouble judgment, about 10 sec. of cranking is necessary. During trouble judgment, about 10 sec. of cranking is necessary.
Preconditions when DTC is set Preconditions when DTC is set
• CMP sensor signal is normal. • CMP sensor signal is normal.
• DTC: 0335, 0336, 0340, 0341 and 1345 are not detected. • DTC: 0335, 0336, 0340, 0341 and 1345 are not detected.
• Engine running • Engine running
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.
• With crank sensor abnormalities, a DTC will not be detected unless the crank rotates 14 times. Especially with low rotation • With crank sensor abnormalities, a DTC will not be detected unless the crank rotates 14 times. Especially with low rotation
such as during idling, the engine will stall before the crank rotates 14 times if there is no CKP sensor signal. Accordingly, such as during idling, the engine will stall before the crank rotates 14 times if there is no CKP sensor signal. Accordingly,
because no DTC is detected and backup mode is not entered, restarting after engine stalling is possible and specifying the because no DTC is detected and backup mode is not entered, restarting after engine stalling is possible and specifying the
problem location will be difficult. When there is an engine stalling problem, increase engine rotation to the maximum with no problem location will be difficult. When there is an engine stalling problem, increase engine rotation to the maximum with no
load and inspect whether a CKP sensor problem is detected during 14 rotations of the crank. If a CKP sensor problem is load and inspect whether a CKP sensor problem is detected during 14 rotations of the crank. If a CKP sensor problem is
detected at the maximum rotation with no load, a DTC will be detected. For intermittent trouble, increase engine rotation to detected at the maximum rotation with no load, a DTC will be detected. For intermittent trouble, increase engine rotation to
the maximum with no load and inspect whether DTC 0355 is detected. the maximum with no load and inspect whether DTC 0355 is detected.

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4021-109 4021-109
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with other 106-GND 1 V or Short circuit with other 106-GND 1 V or
5 value mea- connector. 0V 5 value mea- connector. 0V
signal circuit 107-GND higher signal circuit 107-GND higher
surement • Key switch "ON" surement • Key switch "ON"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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4021-110 4021-110
DTC: 0340 DTC: 0340
CMP (cam position) Sensor Abnormality (no signal) CMP (cam position) Sensor Abnormality (no signal)

The engine cannot start (restart). The engine cannot start (restart).
No change in behavior while engine is turning No change in behavior while engine is turning

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to “Service support check”. Is the action complete? Go to “Service support check”.

Step 2 Yes Step 2 Yes


Check the CMP sensor installation status. Check the CMP sensor installation status.
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Visually inspect the sensor installation status for any 2. Visually inspect the sensor installation status for any
backlash or looseness. Is the action complete? backlash or looseness. Is the action complete?
3. Correct as necessary if a problem is detected. 3. Correct as necessary if a problem is detected.

Step 3 Yes Step 3 Yes


Check the installation status of the CMP sensor, the Check the installation status of the CMP sensor, the
ECM, and the intermediate connector. ECM, and the intermediate connector.
1. Inspect whether there is any backlash or ooseness in 1. Inspect whether there is any backlash or ooseness in
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is Is the action complete? 2. Repair or replace as necessary if a problem is Is the action complete?
detected. detected.

Yes Yes
Step 4 Step 4
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Delete the diagnostic trouble code. See the service 1. Delete the diagnostic trouble code. See the service
support DIAG (trouble diagnosis) screen for No support DIAG (trouble diagnosis) screen for No
information on deleting diagnostic trouble codes. Was a diagnostic trouble code detected? Go to step 15. information on deleting diagnostic trouble codes. Was a diagnostic trouble code detected? Go to step 15.
2. Turn the key switch "OFF" for at least 10 sec. 2. Turn the key switch "OFF" for at least 10 sec.
3. Start the engine and perform a test drive under the 3. Start the engine and perform a test drive under the
"Preconditions when diagnostic trouble code is set". Yes "Preconditions when diagnostic trouble code is set". Yes
4. Confirm the diagnostic trouble code. 4. Confirm the diagnostic trouble code.

Step 5 Step 5
Remove the CMP sensor and inspect to make sure that Remove the CMP sensor and inspect to make sure that
there is no scratching or other damage to the sensor tip. there is no scratching or other damage to the sensor tip.
No No
Is the CMP sensor normal? Go to step 9. Is the CMP sensor normal? Go to step 9.

Step 6 Yes Step 6 Yes


1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the power supply conditions below are present in the power supply
circuit between the ECM and CMP sensor. See the circuit between the ECM and CMP sensor. See the
Breaker Box Inspection Procedure. Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance No • High resistance No
• Short circuit with GND Was a problem detected? • Short circuit with GND Was a problem detected?
1. Repair or replace as necessary if a problem is 1. Repair or replace as necessary if a problem is
detected. detected.

Yes Yes
Go to step 15. Go to step 15.

Step 7 Step 7
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and CMP sensor. See the Breaker No between the ECM and CMP sensor. See the Breaker No
Box Inspection Procedure. Was a problem detected? Box Inspection Procedure. Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
Yes Yes
for sensors on actual machine. Go to step 15. for sensors on actual machine. Go to step 15.
• Disconnection • Disconnection
• High resistance • High resistance
• Short circuit with power supply circuit or ignition • Short circuit with power supply circuit or ignition
power supply circuit power supply circuit
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.
Go to step 8. Go to step 8.

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4021-111 4021-111

From step 7 From step 7


Step 8 Step 8
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the shield circuit conditions below are present in the shield circuit
between the ECM and CMP sensor. between the ECM and CMP sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
• Disconnection Yes • Disconnection Yes
• High resistance • High resistance
• Short circuit with power supply circuit or ignition • Short circuit with power supply circuit or ignition
power supply circuit power supply circuit
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

From step 5 From step 5

Step 9 Step 9
Replace the CMP sensor. Replace the CMP sensor.

Is the action complete? Is the action complete?

Yes Yes
Step 10 Step 10
1. Visually inspect the camshaft gear for abnormalities. 1. Visually inspect the camshaft gear for abnormalities.
2. Check the timing gear reference mark. 2. Check the timing gear reference mark.
3. If a problem was detected, replace or repair. 3. If a problem was detected, replace or repair.

No No
Was a problem detected? Was a problem detected?

Yes Yes
Step 11 Step 11
Replace the supply pump. Replace the supply pump.
Note: Note:
See the "Engine" section in the Service Manual for the See the "Engine" section in the Service Manual for the
work procedures. work procedures.

Is the action complete? Is the action complete?


Step 13 Step 13
1. Check the ECM software version. 1. Check the ECM software version.
Yes Yes
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
"How to Use EMPS". No "How to Use EMPS". No
Step 12 Step 12
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
EGR learning method Yes EGR learning method Yes
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. No 3. Wait about 10 sec. No
Is the action complete? Is the action complete?

Step 14 Yes Step 14 Yes


Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
EGR learning method EGR learning method
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. Is the action complete? 3. Wait about 10 sec. Is the action complete?

Yes Yes

Step 15 Step 15
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. See the service No Has a diagnostic trouble code: 0340 been 2. Delete the diagnostic trouble code. See the service No Has a diagnostic trouble code: 0340 been
support DIAG (trouble diagnosis) screen for detected? support DIAG (trouble diagnosis) screen for detected?
information on deleting diagnostic trouble codes. information on deleting diagnostic trouble codes.
3. Turn the key switch "OFF" for at least 10 sec. Yes 3. Turn the key switch "OFF" for at least 10 sec. Yes
4. Perform a test drive under the "Preconditions when Go to step 2. 4. Perform a test drive under the "Preconditions when Go to step 2.
diagnostic trouble code is set". diagnostic trouble code is set".
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Go to step 16. Go to step 16.

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4021-112 4021-112

From step 15 From step 15

Step 16 Step 16
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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4021-113 4021-113
Block diagram Block diagram

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Recovery from failure Recovery from failure


During trouble judgment, about 10 sec. of cranking is necessary. During trouble judgment, about 10 sec. of cranking is necessary.
Preconditions when DTC is set Preconditions when DTC is set
• CMP sensor signal is normal. • CMP sensor signal is normal.
• DTC: 0335, 0336, 0340, 0341, 1345 and 1635 are not detected. • DTC: 0335, 0336, 0340, 0341, 1345 and 1635 are not detected.
• Engine running • Engine running
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.
• The installation phase of the cam gear is misaligned by one tooth. • The installation phase of the cam gear is misaligned by one tooth.

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4021-114 4021-114
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 99-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 99-Sensor connector 100 Ω or 10 M Ω or
measure- connector. measure- connector.
high resistance power supply terminal lower higher high resistance power supply terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
6 6
Resistance • Remove the sensor Resistance • Remove the sensor
connector. 10 M Ω 100 Ω or connector. 10 M Ω 100 Ω or
Short circuit with GND measure- 99-GND Short circuit with GND measure- 99-GND
or higher lower or higher lower
ment • Key switch "OFF" ment • Key switch "OFF"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 98-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 98-Sensor connector 100 Ω or 10 M Ω or
measure- connector. measure- connector.
high resistance signal terminal lower higher high resistance signal terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
7 7
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with power 18 V or Short circuit with power 18 V or
value mea- connector. 98-GND 0V value mea- connector. 98-GND 0V
supply circuit higher supply circuit higher
surement • Key switch "ON" surement • Key switch "ON"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 100-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 100-Sensor connector 100 Ω or 10 M Ω or
measure- connector. measure- connector.
high resistance shield terminal lower higher high resistance shield terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
8 8
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with power 18 V or Short circuit with power 18 V or
value mea- connector. 100-GND 0V value mea- connector. 100-GND 0V
supply circuit higher supply circuit higher
surement • Key switch "ON" surement • Key switch "ON"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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4021-115 4021-115
DTC: 0341 DTC: 0341
CMP (cam position) Sensor Abnormality (signal abnormality) CMP (cam position) Sensor Abnormality (signal abnormality)

The engine cannot start (restart). The engine cannot start (restart).
No change in behavior while engine is turning No change in behavior while engine is turning

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to Service support check. Is the action complete? Go to Service support check.

Step 2 Yes Step 2 Yes


Check the CMP sensor installation status. Check the CMP sensor installation status.
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Visually inspect the sensor installation status for any 2. Visually inspect the sensor installation status for any
backlash or looseness. Is the action complete? backlash or looseness. Is the action complete?
3. Correct as necessary if a problem is detected. 3. Correct as necessary if a problem is detected.

Step 3 Yes Step 3 Yes


Check the installation status of the CMP sensor, the Check the installation status of the CMP sensor, the
ECM, and the intermediate connector. ECM, and the intermediate connector.
1. Inspect whether there is any backlash or ooseness in 1. Inspect whether there is any backlash or ooseness in
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is Is the action complete? 2. Repair or replace as necessary if a problem is Is the action complete?
detected. detected.

Yes Yes
Step 4 Step 4
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Delete the diagnostic trouble code. See the service 1. Delete the diagnostic trouble code. See the service
support DIAG (trouble diagnosis) screen for No support DIAG (trouble diagnosis) screen for No
information on deleting diagnostic trouble codes. Was a diagnostic trouble code detected? Go to step 11. information on deleting diagnostic trouble codes. Was a diagnostic trouble code detected? Go to step 11.
2. Turn the key switch “OFF” for at least 10 sec. 2. Turn the key switch “OFF” for at least 10 sec.
3. Start the engine and perform a test drive under the 3. Start the engine and perform a test drive under the
“Preconditions when diagnostic trouble code is set”. Yes “Preconditions when diagnostic trouble code is set”. Yes
4. Confirm the diagnostic trouble code. 4. Confirm the diagnostic trouble code.

Step 5 Step 5
Remove the CMP sensor and inspect to make sure that Remove the CMP sensor and inspect to make sure that
there is no scratching or other damage to the sensor tip. there is no scratching or other damage to the sensor tip.
No No
Is the CMP sensor normal? Go to step 8. Is the CMP sensor normal? Go to step 8.

Yes Yes

Step 6 Step 6
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the harness from the CMP sensor. 2. Remove the harness from the CMP sensor.
3. Connect the breaker box or DMM between the CMP 3. Connect the breaker box or DMM between the CMP
sensor terminals. sensor terminals.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures No If there is no breaker box, see the Inspection procedures No
for sensors on actual machine. Reference value 0 V for sensors on actual machine. Reference value 0 V
Turn the key switch “ON”. Is the DMM display the reference value? Turn the key switch “ON”. Is the DMM display the reference value?

Yes Yes
Go to step 8. Go to step 8.

Step 7 Step 7
1. Use the breaker box or DMM to inspect for a short 1. Use the breaker box or DMM to inspect for a short
with another signal circuit in the ECM or CKP sensor with another signal circuit in the ECM or CKP sensor
circuit. circuit.
See the Breaker Box Inspection Procedure. No See the Breaker Box Inspection Procedure. No
Was a problem detected? Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. Yes for sensors on actual machine. Yes
2. Repair or replace as necessary if a problem is Go to step 14. 2. Repair or replace as necessary if a problem is Go to step 14.
detected. detected.

Go to step 9. Go to step 9.

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4021-116 4021-116

From step 6 From step 6

Step 8 Step 8
Replace the CMP sensor. Replace the CMP sensor.

Is the action complete? Is the action complete?

Yes Yes

Step 9 From step 7 Step 9 From step 7


1. Visually inspect the camshaft gear for abnormalities. 1. Visually inspect the camshaft gear for abnormalities.
2. Check the timing gear reference mark. 2. Check the timing gear reference mark.
3. If a problem was detected, replace or repair. 3. If a problem was detected, replace or repair.

No No
Was a problem detected? Was a problem detected?

Yes Yes

Step 10 Step 10
Replace the supply pump. Replace the supply pump.
Note: Note:
See the “Engine” section in the Service Manual for the See the “Engine” section in the Service Manual for the
work procedures. work procedures.
Is the action complete? Is the action complete?

Yes Yes

Step 12 No Step 11 Step 12 No Step 11


1. Check the ECM software version. Is there an EMPS? 1. Check the ECM software version. Is there an EMPS?
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. Yes version is necessary. Yes
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
“How to Use EMPS”. “How to Use EMPS”.
Notes: Notes:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
No No
2. Turn the key switch “OFF”. Is the action complete? 2. Turn the key switch “OFF”. Is the action complete?
3. Wait about 10 sec. 3. Wait about 10 sec.

Yes Yes

Step 13 Step 13
Replace the ECM. Replace the ECM.
Notes: Notes:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Is the action complete? 3. Wait about 10 sec. Is the action complete?

Yes Yes

Step 14 Step 14
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. No 2. Delete the diagnostic trouble code. No
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0341 been See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0341 been
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
3. Turn the key switch “OFF” for at least 10 sec. Yes 3. Turn the key switch “OFF” for at least 10 sec. Yes
4. Perform a test drive under the “Preconditions when Go to step 2. 4. Perform a test drive under the “Preconditions when Go to step 2.
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 15 Step 15
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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4021-117 4021-117
Block diagram Block diagram

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Recovery from failure Recovery from failure


During trouble judgment, about 10 sec. of cranking is necessary. During trouble judgment, about 10 sec. of cranking is necessary.
Preconditions when DTC is set Preconditions when DTC is set
• CKP sensor signal is normal. • CKP sensor signal is normal.
• DTC: 0335, 0336, 0340, 0341, 1345 and 1635 are not detected. • DTC: 0335, 0336, 0340, 0341, 1345 and 1635 are not detected.
• Engine running • Engine running
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with other 1 V or Short circuit with other 1 V or
7 value mea- connector. 98-GND 0V 7 value mea- connector. 98-GND 0V
signal circuit higher signal circuit higher
surement • Key switch "ON" surement • Key switch "ON"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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DTC: 0380 DTC: 0380
Glow Relay Circuit Abnormality Glow Relay Circuit Abnormality

Low-temperature starting defect Low-temperature starting defect

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to Service support check. Is the action complete? Go to Service support check.

Yes Yes

Step 2 No Step 2 No
Go to step 17. Go to step 17.
Do you have a scan tool (KW communication)? Do you have a scan tool (KW communication)?
Step 3 Step 3
1. Turn the key switch to the “ON” position. 1. Turn the key switch to the “ON” position.
Yes Yes
2. Use the scan tool to check the “Glow relay” display in 2. Use the scan tool to check the “Glow relay” display in
the data display. the data display.

No No
Is the “Glow relay” display “ON”? Is the “Glow relay” display “ON”?

Yes Yes
Step 4 Step 4
1. Turn the key switch to the “ON” position. 1. Turn the key switch to the “ON” position.
2. Hold as is for at least 10 sec. 2. Hold as is for at least 10 sec.
3. Use the scan tool to check the “Glow relay” display in No 3. Use the scan tool to check the “Glow relay” display in No
the data display. Is the “Glow relay” display “OFF”? Go to step 9. the data display. Is the “Glow relay” display “OFF”? Go to step 9.

Yes Yes
Go to diagnostic aid. Go to diagnostic aid.

Step 5 Step 5
Check the installation status of the glow relay, ECM Check the installation status of the glow relay, ECM
connector, and intermediate connector. connector, and intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Correct as necessary if a problem is detected. No 2. Correct as necessary if a problem is detected. No
Was a problem detected? Was a problem detected?

Step 6 Yes Step 6 Yes


1. Turn the key switch “OFF”. Go to step 12. 1. Turn the key switch “OFF”. Go to step 12.
2. Remove the glow relay. 2. Remove the glow relay.
3. Use a jumper cable to create a short circuit between 3. Use a jumper cable to create a short circuit between
terminals 2 and 4 of the glow relay installation section. terminals 2 and 4 of the glow relay installation section.
4. Turn the key switch “ON”. 4. Turn the key switch “ON”.
5. Use the scan tool to check the “Glow relay” display in 5. Use the scan tool to check the “Glow relay” display in
the data display. the data display.

No No
Is the “Glow relay” display “ON”? Is the “Glow relay” display “ON”?

Yes Yes
Go to step 11. Go to step 11.

Step 7 Step 7
1. Inspect whether the conditions below are present in 1. Inspect whether the conditions below are present in
the circuit between the fuse and the glow relay. the circuit between the fuse and the glow relay.
• Disconnection • Disconnection
• Short circuit with GND circuit No • Short circuit with GND circuit No
• High resistance Was a problem detected? • High resistance Was a problem detected?
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Yes Yes
Go to step 12. Go to step 12.

Go to step 8. Go to step 8.

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From step 7 From step 7


Step 8 Step 8
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the circuit between conditions below are present in the circuit between
the glow relay and ECM. the glow relay and ECM.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
Was a problem detected? Was a problem detected?
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
• Disconnection Yes • Disconnection Yes
• Short circuit with GND circuit • Short circuit with GND circuit
• High resistance • High resistance
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 9 Step 9
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the glow relay. 2. Remove the glow relay.
3. Turn the key switch “ON”. No 3. Turn the key switch “ON”. No
4. Use the scan tool to check the “Glow relay” display in Is the “Glow relay” display “OFF”? 4. Use the scan tool to check the “Glow relay” display in Is the “Glow relay” display “OFF”?
the data display. the data display.

Yes Yes

Step 10 Step 10
1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
short circuit with the power supply circuit or ignition short circuit with the power supply circuit or ignition
power supply circuit is present in the circuit between power supply circuit is present in the circuit between
the glow relay and the ECM. the glow relay and the ECM.
See the Breaker Box Inspection Procedure. No See the Breaker Box Inspection Procedure. No
Note: Was a problem detected? Note: Was a problem detected?
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes

Step 11 Step 11
Replace the glow relay. Replace the glow relay.

Is the action complete? Is the action complete?

Step 13 Yes Step 13 Yes


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. No version is necessary. No
For details on checking the ECM and the rewriting, see Step 12 For details on checking the ECM and the rewriting, see Step 12
“How to Use EMPS”. Is there an EMPS? “How to Use EMPS”. Is there an EMPS?
Note: Note:
When ECM replacement or rewriting is performed, Yes When ECM replacement or rewriting is performed, Yes
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
No No
2. Turn the key switch “OFF”. Is the action complete? 2. Turn the key switch “OFF”. Is the action complete?
3. Wait about 10 sec. 3. Wait about 10 sec.

Yes Yes
Go to step 15. Go to step 15.
Step 14 Step 14
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. Is the action complete? 1. Turn the key switch “ON”. Is the action complete?
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

Go to step 15. Go to step 15.

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From step 14 From step 14

Step 15 Step 15
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0380 been See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0380 been
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when Go to step 12. 4. Perform a test drive under the “Preconditions when Go to step 12.
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 16 Step 16
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

From step 2 From step 2

Check the installation status of the glow relay, ECM Check the installation status of the glow relay, ECM
connector, and intermediate connector. connector, and intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. No the installation of the connectors. No
2. Correct as necessary if a problem is detected. Was a problem detected? Go to step 7. 2. Correct as necessary if a problem is detected. Was a problem detected? Go to step 7.

Yes Yes

Go to step 12. Go to step 12.

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Block diagram Block diagram

RELAY R2 RELAY R2
GLOW GLOW

FUSE F3 FUSE F3
(KEY) (KEY)

KEY SWITCH GLOW PLUG KEY SWITCH GLOW PLUG

RELAY BATTERY RELAY BATTERY


BATTERY BATTERY
(24 V) (24 V)

FUSIBLE LINK FUSIBLE LINK


F1 F1

BOX FUSE BOX FUSE


(F8) (F8)

659) 659)

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 16 V or higher and 32 V or lower. • Key switch input voltage is 16 V or higher and 32 V or lower.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance Resistance
Disconnection/ • Remove the relay. 10-FL12 connector 10 M Ω 10 M Ω or Disconnection/ • Remove the relay. 10-FL12 connector 10 M Ω 10 M Ω or
measure- measure-
high resistance • Key switch "OFF" No. 1 terminal or lower higher high resistance • Key switch "OFF" No. 1 terminal or lower higher
ment ment
8 8
Resistance Resistance
• Remove the relay. 10 M Ω 10 M Ω or • Remove the relay. 10 M Ω 10 M Ω or
Short circuit with GND measure- 10-GND Short circuit with GND measure- 10-GND
• Key switch "OFF" or higher lower • Key switch "OFF" or higher lower
ment ment
Voltage Voltage
Short circuit with power • Remove the relay. 18 V or Short circuit with power • Remove the relay. 18 V or
10 value mea- 10-GND 0V 10 value mea- 10-GND 0V
supply circuit • Key switch "ON" higher supply circuit • Key switch "ON" higher
surement surement

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4021-124 4021-124
DTC: 0487 DTC: 0487
EGR Position Sensor Abnormality EGR Position Sensor Abnormality

No effect on operation No effect on operation

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to Service support check. Is the action complete? Go to Service support check.
Step 2 Step 2
Check the installation status of the EGR valve connector, Yes Check the installation status of the EGR valve connector, Yes
the ECM, and the intermediate connector. the ECM, and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.
No No
Was a problem detected? Was a problem detected?

Step 3 Yes Step 3 Yes


1. Use the breaker box or DMM to check whether the Go to step 10. 1. Use the breaker box or DMM to check whether the Go to step 10.
conditions below are present in the wiring between conditions below are present in the wiring between
the ECM and the EGR position sensor. the ECM and the EGR position sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. No for sensors on actual machine. No
• Short circuit with EGR position sensor GND circuit Is the action complete? • Short circuit with EGR position sensor GND circuit Is the action complete?
• Short circuit with GND • Short circuit with GND
• Disconnection • Disconnection
Yes Yes
• High resistance Go to step 10. • High resistance Go to step 10.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 4 Step 4
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0487 been No See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0487 been No
Go to diagnostic aid. Go to diagnostic aid.
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
3. Turn the key switch “OFF”, wait at least 10 sec., then Yes 3. Turn the key switch “OFF”, wait at least 10 sec., then Yes
start the engine. start the engine.
4. Warm up the engine until the coolant emperature is 4. Warm up the engine until the coolant emperature is
higher than 80 °C. higher than 80 °C.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 5 Step 5
Replace the EGR valve (EGR position sensor). Replace the EGR valve (EGR position sensor).
Note: Note:
See the “Engine” section in the Service Manual for the See the “Engine” section in the Service Manual for the
work procedures. Is the action complete? work procedures. Is the action complete?

Yes Yes

Step 6 Step 6
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0487 been No See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0487 been No
Go to step 11. Go to step 11.
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
3. Turn the key switch “OFF”, wait at least 10 sec., then Yes 3. Turn the key switch “OFF”, wait at least 10 sec., then Yes
start the engine. start the engine.
4. Warm up the engine until the coolant temperature is No 4. Warm up the engine until the coolant temperature is No
Step 7 Step 7
higher than 80 °C. higher than 80 °C.
Is there an EMPS? Is there an EMPS?
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Yes Yes

Go to step 9. Go to step 8. Go to step 9. Go to step 8.

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Step 8 From step 7 Step 8 From step 7


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
“How to Use EMPS”. No “How to Use EMPS”. No
Note: Is the action complete? Note: Is the action complete?
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] Yes [EGR learning method] Yes
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 9 Step 9
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. Is the action complete? perform EGR learning. Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. Yes 2. Turn the key switch “OFF”. Yes
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 10 Step 10
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble No screen for information on deleting diagnostic trouble No
codes. Has a diagnostic trouble code: 0487 been codes. Has a diagnostic trouble code: 0487 been
3. Turn the key switch “OFF”, wait at least 10 sec., then detected? 3. Turn the key switch “OFF”, wait at least 10 sec., then detected?
start the engine. start the engine.
4. Warm up the engine until the coolant temperature is Yes 4. Warm up the engine until the coolant temperature is Yes
higher than 80 °C. Go to step 2. higher than 80 °C. Go to step 2.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 11 Step 11
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has a diagnostic trouble code: 0487 been No Has a diagnostic trouble code: 0487 been No
Check repair. Check repair.
detected? detected?

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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4021-126 4021-126
Block diagram Block diagram

EGR MOTOR EGR MOTOR

EGR POSITION SENSOR EGR POSITION SENSOR

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Main relay input voltage is 18 V or higher. • Main relay input voltage is 18 V or higher.
• DTC: 1630, 1635 are not detected. • DTC: 1630, 1635 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem, harness routing problem • Harness connector connection problem, harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value

Resistance • Remove the EGR valve 87-EGR valve connec- Resistance • Remove the EGR valve 87-EGR valve connec-
Disconnection/
connector. 100 Ω or 10 M Ω or Disconnection/
connector. 100 Ω or 10 M Ω or
3 measure- tor sensor power sup- 3 measure- tor sensor power sup-
high resistance lower higher high resistance lower higher
ment • Key switch "OFF" ply terminal ment • Key switch "OFF" ply terminal

92-101 92-101
93-101 93-101
Resistance • Remove the EGR valve Resistance • Remove the EGR valve
Short circuit with GND 94-101 10 M Ω 100 M Ω or Short circuit with GND 94-101 10 M Ω 100 M Ω or
measure- connector. measure- connector.
circuit/GND 92-GND or higher lower circuit/GND 92-GND or higher lower
ment • Key switch "OFF" ment • Key switch "OFF"
93-GND 93-GND
94-GND 94-GND
92-EGR valve connec- 92-EGR valve connec-
4 tor position sensor sig- 4 tor position sensor sig-
nal W terminal nal W terminal
Resistance • Remove the EGR valve 93-EGR valve connec- Resistance • Remove the EGR valve 93-EGR valve connec-
Disconnection/
connector. 100 Ω or 10 M Ω or Disconnection/
connector. 100 Ω or 10 M Ω or
measure- tor position sensor sig- measure- tor position sensor sig-
high resistance lower higher high resistance lower higher
ment • Key switch "OFF" nal V terminal ment • Key switch "OFF" nal V terminal
94-EGR valve connec- 94-EGR valve connec-
tor position sensor sig- tor position sensor sig-
nal U terminal nal U terminal

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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DTC: 0488 DTC: 0488
EGR Valve Control Abnormality EGR Valve Control Abnormality

No effect on operation No effect on operation

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to Service support check. Is the action complete? Go to Service support check.

Yes Yes

Step 2 No Step 2 No
Go to step 13. Go to step 13.
Do you have a scan tool (KW communication)? Do you have a scan tool (KW communication)?
Step 3 Step 3
1. Use the scan tool to perform the “EGR control test”. 1. Use the scan tool to perform the “EGR control test”.
Yes Yes
2. Press the “UP” “DOWN” soft key. 2. Press the “UP” “DOWN” soft key.
3. Check the “EGR position” value. 3. Check the “EGR position” value.

No Reference value ± 3% No Reference value ± 3%


Is the “EGR position” value within the reference Is the “EGR position” value within the reference
Step 4 value range? Step 4 value range?
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
Yes Yes
1. Delete the diagnostic trouble code. 1. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. No codes. No
Has a diagnostic trouble code: 0488 been Has a diagnostic trouble code: 0488 been
2. Turn the key switch "OFF", wait at least 0 sec., then Go to diagnostic aid. 2. Turn the key switch "OFF", wait at least 0 sec., then Go to diagnostic aid.
detected? detected?
start the engine. start the engine.
3. Warm up the engine until the coolant temperature is 3. Warm up the engine until the coolant temperature is
higher than 80 °C. Yes higher than 80 °C. Yes
4. Confirm the diagnostic trouble code. Go to step 8. 4. Confirm the diagnostic trouble code. Go to step 8.

Step 5 Step 5
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the wiring between conditions below are present in the wiring between
the ECM and the EGR position sensor. the ECM and the EGR position sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: No Notes: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• Short circuit with GND Yes • Short circuit with GND Yes
• Short circuit with power supply circuit or ignition Go to step 11. • Short circuit with power supply circuit or ignition Go to step 11.
power supply circuit power supply circuit
• High resistance • High resistance
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 6 Step 6
Replace the EGR valve (EGR position sensor). Replace the EGR valve (EGR position sensor).
Notes: Notes:
See the “Engine” section in the Service Manual for the See the “Engine” section in the Service Manual for the
work procedures. work procedures.
Is the action complete? Is the action complete?

Step 7 Yes Step 7 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0488 been No See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 0488 been No
Go to step 12. Go to step 12.
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
3. Turn the key switch “OFF”, wait at least 10 sec., then Yes 3. Turn the key switch “OFF”, wait at least 10 sec., then Yes
start the engine. start the engine.
4. Warm up the engine until the coolant temperature is Go to step 8. 4. Warm up the engine until the coolant temperature is Go to step 8.
higher than 80 °C. higher than 80 °C.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

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Step 9 From step 7 Step 9 From step 7


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. No version is necessary. No
For details on checking the ECM and the rewriting, see Step 8 For details on checking the ECM and the rewriting, see Step 8
“How to Use EMPS” in this chapter. Is there an EMPS? “How to Use EMPS” in this chapter. Is there an EMPS?
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
No No
2. Turn the key switch “OFF”. Is the action complete? 2. Turn the key switch “OFF”. Is the action complete?
3. Wait about 10 sec. 3. Wait about 10 sec.

Yes Yes

Step 10 Step 10
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. Is the action complete? 1. Turn the key switch “ON”. Is the action complete?
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Yes Yes

Step 11 Step 11
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble No screen for information on deleting diagnostic trouble No
codes. Has a diagnostic trouble code: 0488 been codes. Has a diagnostic trouble code: 0488 been
3. Turn the key switch “OFF”, wait at least 10 sec., then detected? 3. Turn the key switch “OFF”, wait at least 10 sec., then detected?
start the engine. start the engine.
4. Warm up the engine until the coolant temperature is Yes 4. Warm up the engine until the coolant temperature is Yes
higher than 80 °C. Go to step 2. higher than 80 °C. Go to step 2.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 12 Step 12
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

From step 2 From step 2

Step 13 Step 13
1. Remove the EGR valve. 1. Remove the EGR valve.
2. Check the EGR valve for sticking, clogging, or the like. 2. Check the EGR valve for sticking, clogging, or the like.
3. Correct as necessary if a problem is detected. No 3. Correct as necessary if a problem is detected. No
Was a problem detected? Go to step 4. Was a problem detected? Go to step 4.

Yes Yes

Go to step 5. Go to step 5.

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Block diagram Block diagram

EGR MOTOR EGR MOTOR

EGR POSITION SENSOR EGR POSITION SENSOR

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• DTC: 0487, 1630, and 1635 are not detected. • DTC: 0487, 1630, and 1635 are not detected.
• Main relay input voltage is higher than 20 V and lower than 32 V. • Main relay input voltage is higher than 20 V and lower than 32 V.
• Difference between target EGR degree of opening and actual degree of opening is 20 % or less. • Difference between target EGR degree of opening and actual degree of opening is 20 % or less.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value

Voltage • Remove the EGR valve 111 -GND Voltage • Remove the EGR valve 111 -GND
Short circuit with power 18 V or Short circuit with power 18 V or
value mea- connector. 103 -GND 0V value mea- connector. 103 -GND 0V
supply circuit higher supply circuit higher
surement • Key switch "ON" 110 -GND surement • Key switch "ON" 110 -GND

Resistance • Remove the EGR valve 111 -GND Resistance • Remove the EGR valve 111 -GND
connector. 10 M Ω 100 Ω or connector. 10 M Ω 100 Ω or
Short circuit with GND measure- 103 -GND Short circuit with GND measure- 103 -GND
or higher lower or higher lower
ment • Key switch "OFF" 110 -GND ment • Key switch "OFF" 110 -GND

5 111-EGR valve con- 5 111-EGR valve con-


nector motor nector motor
Drive U terminal Drive U terminal
Resistance • Remove the EGR valve 103-EGR valve con- Resistance • Remove the EGR valve 103-EGR valve con-
Disconnection/
connector. 100 Ω or 10 M Ω or Disconnection/
connector. 100 Ω or 10 M Ω or
measure- nector motor measure- nector motor
high resistance lower higher high resistance lower higher
ment • Key switch "OFF" Drive V terminal ment • Key switch "OFF" Drive V terminal
110-EGR valve con- 110-EGR valve con-
nector motor nector motor
Drive W terminal Drive W terminal

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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DTC: 0522 DTC: 0522
Engine Oil Pressure Sensor Abnormality (abnormally low voltage) Engine Oil Pressure Sensor Abnormality (abnormally low voltage)

No effect on operation No effect on operation

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Execution of service support check Is the action complete? Execution of service support check

Yes Yes

Step 3 Step 3
Use the scan tool to check the engine oil pressure sensor No Use the scan tool to check the engine oil pressure sensor No
value. Step 2 value. Step 2
Go to step 6. Go to step 6.
1. Connect the scan tool. Do you have a scan tool (KW communication)? 1. Connect the scan tool. Do you have a scan tool (KW communication)?
2. Start the engine. 2. Start the engine.
3. Use the scan tool to check the “Engine oil pressure Yes 3. Use the scan tool to check the “Engine oil pressure Yes
sensor” display. sensor” display.

Reference value 0.1 V No Reference value 0.1 V No


Is the “Engine oil pressure sensor” value at or Go to diagnostic aid. Is the “Engine oil pressure sensor” value at or Go to diagnostic aid.
below the reference value? below the reference value?
Step 4 Step 4
Check the installation status of the engine oil pressure Yes Check the installation status of the engine oil pressure Yes
sensor, the ECM and the intermediate connector. sensor, the ECM and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is No 2. Repair or replace as necessary if a problem is No
detected. Was a problem detected? detected. Was a problem detected?

Yes Yes
Go to step 11. Go to step 11.
Step 5 Step 5
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the engine oil pressure sensor connector. 2. Remove the engine oil pressure sensor connector.
3. Turn the key switch “ON”. 3. Turn the key switch “ON”.
4. Use the scan tool to check the “Engine oil pressure 4. Use the scan tool to check the “Engine oil pressure
sensor” display. No Reference value 0 V sensor” display. No Reference value 0 V
Is the “Engine oil pressure sensor” value at or Is the “Engine oil pressure sensor” value at or
above the reference value? above the reference value?

Step 6 Yes Step 6 Yes


1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and engine oil pressure sensor. between the ECM and engine oil pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection If there is no breaker box, see the Inspection
procedures for sensors on actual machine. No procedures for sensors on actual machine. No
• Short circuit with the engine oil pressure sensor GND Was a problem detected? • Short circuit with the engine oil pressure sensor GND Was a problem detected?
circuit circuit
• Short circuit with GND • Short circuit with GND
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 11. Go to step 11.

Step 7 Step 7
Replace the engine oil pressure sensor. Replace the engine oil pressure sensor.

Is the action complete? Is the action complete?

Yes Yes
Go to step 11. Go to step 11.

Go to step 8. Go to step 8.

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4021-133 4021-133

Step 9 From step 6 Step 9 From step 6


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. No version is necessary. No
For details on checking the ECM and the rewriting, see Step 8 For details on checking the ECM and the rewriting, see Step 8
“How to Use EMPS” in this chapter. Is there an EMPS? “How to Use EMPS” in this chapter. Is there an EMPS?
Note: Note:
When ECM replacement or rewriting is performed, Yes When ECM replacement or rewriting is performed, Yes
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
No No
2. Turn the key switch “OFF”. Is the action complete? 2. Turn the key switch “OFF”. Is the action complete?
3. Wait about 10 sec. 3. Wait about 10 sec.

Yes Yes

Step 10 Step 10
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. Is the action complete? 1. Turn the key switch “ON”. Is the action complete?
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Yes Yes

Step 11 Step 11
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble No Has a diagnostic trouble code: 0522 been screen for information on deleting diagnostic trouble No Has a diagnostic trouble code: 0522 been
codes. detected? codes. detected?
3. Turn the key switch “OFF”, wait at least 10 sec. 3. Turn the key switch “OFF”, wait at least 10 sec.
4. Perform a test drive under the “Preconditions when 4. Perform a test drive under the “Preconditions when
diagnostic trouble code is set”. Yes diagnostic trouble code is set”. Yes
Go to step 2. Go to step 2.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 12 Step 12
1. Start the engine. 1. Start the engine.
2. Check the engine oil pressure display. 2. Check the engine oil pressure display.

Reference value 1016 kPa No Reference value 1016 kPa No


(error display value) Go to diagnostic aid. (error display value) Go to diagnostic aid.
Step 13 Is the engine oil pressure display Step 13 Is the engine oil pressure display
Check the installation status of the engine oil pressure showing the error display value? Check the installation status of the engine oil pressure showing the error display value?
sensor, the ECM and the intermediate connector. sensor, the ECM and the intermediate connector.
1. Inspect whether there is any backlash or looseness in Yes 1. Inspect whether there is any backlash or looseness in Yes
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 11. Go to step 11.
Step 14 Step 14
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and engine oil pressure sensor. between the ECM and engine oil pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
• Short circuit with engine oil pressure sensor GND cir- • Short circuit with engine oil pressure sensor GND cir-
cuit Yes cuit Yes
• Short circuit with GND Go to step 11. • Short circuit with GND Go to step 11.
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

Go to step 7. Go to step 7.

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4021-134 4021-134
Block diagram Block diagram

OIL PRESS. SENSOR OIL PRESS. SENSOR

WATER TEMP. SENSOR WATER TEMP. SENSOR

FUEL TEMP. SENSOR FUEL TEMP. SENSOR

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1633 is not detected. • DTC: 1633 is not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-135 4021-135
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
67-79 67-79
Resistance • Remove the sensor Resistance • Remove the sensor
Short circuit with GND 67-GND 10 M Ω 100 Ω or Short circuit with GND 67-GND 10 M Ω 100 Ω or
6 measure- connector. 6 measure- connector.
circuit/GND 80-79 or higher lower circuit/GND 80-79 or higher lower
ment • Key switch "ON" ment • Key switch "ON"
80-GND 80-GND

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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4021-136 4021-136
DTC: 0523 DTC: 0523
Engine Oil Pressure Sensor Abnormality (abnormally high voltage) Engine Oil Pressure Sensor Abnormality (abnormally high voltage)

No effect on operation No effect on operation

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Execution of service support check Is the action complete? Execution of service support check

Yes Yes

Step 3 Step 3
Use the scan tool to check the engine oil pressure sensor No Use the scan tool to check the engine oil pressure sensor No
value. Step 2 value. Step 2
Go to step 15. Go to step 15.
1. Connect the scan tool. Do you have a scan tool (KW communication)? 1. Connect the scan tool. Do you have a scan tool (KW communication)?
2. Start the engine. 2. Start the engine.
3. Use the scan tool to check the “Engine oil pressure Yes 3. Use the scan tool to check the “Engine oil pressure Yes
sensor” display. sensor” display.

Reference value 4.85 V No Reference value 4.85 V No


Is the “Engine oil pressure sensor” value at or Go to diagnostic aid. Is the “Engine oil pressure sensor” value at or Go to diagnostic aid.
below the reference value? below the reference value?
Step 4 Step 4
Check the installation status of the engine oil pressure Yes Check the installation status of the engine oil pressure Yes
sensor, the ECM and the intermediate connector. sensor, the ECM and the intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Repair or replace as necessary if a problem is No 2. Repair or replace as necessary if a problem is No
detected. Was a problem detected? detected. Was a problem detected?

Yes Yes
Go to step 13. Go to step 13.
Step 5 Step 5
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the engine oil pressure sensor connector. 2. Remove the engine oil pressure sensor connector.
3. Use a jumper cable to create a short circuit between 3. Use a jumper cable to create a short circuit between
the signal terminal of the engine oil pressure sensor the signal terminal of the engine oil pressure sensor
connector and the GND terminal. No Reference value 0 V connector and the GND terminal. No Reference value 0 V
4. Turn the key switch “ON”. Is the “Engine oil pressure sensor” value at or 4. Turn the key switch “ON”. Is the “Engine oil pressure sensor” value at or
5. Use the scan tool to check the “Engine oil pressure above the reference value? 5. Use the scan tool to check the “Engine oil pressure above the reference value?
sensor” display. sensor” display.
Yes Yes
Go to step 9. Go to step 9.

Step 6 Step 6
1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
short circuit with the power supply circuit or ignition short circuit with the power supply circuit or ignition
power supply circuit is present in the signal circuit power supply circuit is present in the signal circuit
between the ECM and engine oil pressure sensor. between the ECM and engine oil pressure sensor.
See the Breaker Box Inspection Procedure. No See the Breaker Box Inspection Procedure. No
Note: Was a problem detected? Note: Was a problem detected?
If there is no breaker box, see the Inspection If there is no breaker box, see the Inspection
procedures for sensors on actual machine. procedures for sensors on actual machine.
Important: Yes Important: Yes
If the engine oil pressure sensor circuit is short-circuited Go to step 13. If the engine oil pressure sensor circuit is short-circuited Go to step 13.
to the power supply circuit, there may be sensors that are to the power supply circuit, there may be sensors that are
damaged. damaged.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 7 Step 7
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and engine oil pressure sensor. between the ECM and engine oil pressure sensor.
See the Breaker Box Inspection Procedure. No See the Breaker Box Inspection Procedure. No
Is the action complete? Is the action complete?
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. Yes for sensors on actual machine. Yes
• Disconnection Go to step 13. • Disconnection Go to step 13.
• High resistance • High resistance
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

Go to step 8. Go to step 8.

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4021-137 4021-137

Step 8 From step 6 Step 8 From step 6


1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the circuit between conditions below are present in the circuit between
the ECM and engine oil pressure sensor. the ECM and engine oil pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

From step 5 From step 5

Step 9 Step 9
Replace the engine oil pressure sensor. Replace the engine oil pressure sensor.

Is the action complete? Is the action complete?


Step 11 Step 11
1. Check the ECM software version. 1. Check the ECM software version.
Yes Yes
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
“How to Use EMPS”. “How to Use EMPS”.
Note: Note:
When ECM replacement or rewriting is performed, No Step 10 When ECM replacement or rewriting is performed, No Step 10
perform EGR learning. Is there an EMPS? perform EGR learning. Is there an EMPS?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 12 Step 12
Replace the ECM. Yes Replace the ECM. Yes
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Step 13 Yes Step 13 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble No Has a diagnostic trouble code: 0523 been screen for information on deleting diagnostic trouble No Has a diagnostic trouble code: 0523 been
codes. detected? codes. detected?
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when 4. Perform a test drive under the “Preconditions when
diagnostic trouble code is set”. Yes diagnostic trouble code is set”. Yes
Go to step 2. Go to step 2.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 14 Step 14
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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4021-138 4021-138

From step 3 From step 3

Step 15 Step 15
1. Start the engine 1. Start the engine
2. Check the engine oil pressure display. 2. Check the engine oil pressure display.

Reference value 1016 kPa No Reference value 1016 kPa No


(error display value) Go to diagnostic aid. (error display value) Go to diagnostic aid.
Step 16 Is the engine oil pressure display Step 16 Is the engine oil pressure display
1. Use the breaker box or DMM to inspect whether a showing the error display value? 1. Use the breaker box or DMM to inspect whether a showing the error display value?
short circuit with the power supply circuit or ignition short circuit with the power supply circuit or ignition
power supply circuit is present in the signal circuit Yes power supply circuit is present in the signal circuit Yes
between the ECM and engine oil pressure sensor. between the ECM and engine oil pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
Important: No Important: No
If the engine oil pressure sensor circuit is short-circuited Was a problem detected? If the engine oil pressure sensor circuit is short-circuited Was a problem detected?
to the power supply circuit, there may be sensors that are to the power supply circuit, there may be sensors that are
damaged. Yes damaged. Yes
2. Repair or replace as necessary if a problem is Go to step 13. 2. Repair or replace as necessary if a problem is Go to step 13.
detected. detected.

Step 17 Step 17
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and engine oil pressure sensor. No between the ECM and engine oil pressure sensor. No
See the Breaker Box Inspection Procedure. Was a problem detected? See the Breaker Box Inspection Procedure. Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures Yes If there is no breaker box, see the Inspection procedures Yes
for sensors on actual machine. Go to step 13. for sensors on actual machine. Go to step 13.
• Disconnection • Disconnection
• High resistance • High resistance
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

Step 18 Step 18
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the GND circuit conditions below are present in the GND circuit
between the ECM and engine oil pressure sensor. between the ECM and engine oil pressure sensor.
See the Breaker Box Inspection Procedure. No See the Breaker Box Inspection Procedure. No
Was a problem detected? Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. Yes for sensors on actual machine. Yes
• Disconnection Go to step 13. • Disconnection Go to step 13.
• High resistance • High resistance
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

Go to step 9. Go to step 9.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-139 4021-139
Block diagram Block diagram

OIL PRESS. SENSOR OIL PRESS. SENSOR

WATER TEMP. SENSOR WATER TEMP. SENSOR

FUEL TEMP. SENSOR FUEL TEMP. SENSOR

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1633 is not detected. • DTC: 1633 is not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-140 4021-140
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with power 18 V or Short circuit with power 18 V or
6 value mea- connector. 67-GND 0V 6 value mea- connector. 67-GND 0V
supply circuit higher supply circuit higher
surement • Key switch "ON" surement • Key switch "ON"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 67-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 67-Sensor connector 100 Ω or 10 M Ω or
7 measure- connector. 7 measure- connector.
high resistance signal terminal lower higher high resistance signal terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 79-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 79-Sensor connector 100 Ω or 10 M Ω or
8 measure- connector. 8 measure- connector.
high resistance GND terminal lower higher high resistance GND terminal lower higher
ment • Key switch "ON" ment • Key switch "ON"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-141 4021-141
DTC: 0601 DTC: 0601
ROM Abnormality ROM Abnormality

Engine stop Engine stop

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to “Service support check”. Is the action complete? Go to “Service support check”.
Step 2 Step 2
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Delete the diagnostic trouble code. Yes 1. Delete the diagnostic trouble code. Yes
2. See the service support DIAG (trouble diagnosis) 2. See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. No codes. No
3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0601 been 3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0601 been
Go to diagnostic aid. Go to diagnostic aid.
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes

No Step 3 No Step 3
Is there an EMPS? Is there an EMPS?
Step 4 Step 4
1. Check the ECM software version. 1. Check the ECM software version.
Yes Yes
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
“How to Use EMPS”. “How to Use EMPS”.
Note: Note:
When ECM replacement or rewriting is performed, No When ECM replacement or rewriting is performed, No
perform EGR learning. Is the action complete? perform EGR learning. Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 5 Step 5
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. Is the action complete? perform EGR learning. Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. Yes 2. Turn the key switch “OFF”. Yes
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 6 Step 6
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-142 4021-142
DTC: 0603 DTC: 0603
EEPROM Abnormality EEPROM Abnormality

No effect on operation No effect on operation

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to “Service support check”. Is the action complete? Go to “Service support check”.
Step 2 Step 2
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Delete the diagnostic trouble code. Yes 1. Delete the diagnostic trouble code. Yes
2. See the service support DIAG (trouble diagnosis) 2. See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. No codes. No
3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0603 been 3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0603 been
Go to diagnostic aid. Go to diagnostic aid.
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes

No Step 3 No Step 3
Is there an EMPS? Is there an EMPS?
Step 4 Step 4
1. Check the ECM software version. 1. Check the ECM software version.
Yes Yes
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
“How to Use EMPS”. “How to Use EMPS”.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. Is the action complete? perform EGR learning. Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 5 Step 5
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. Is the action complete? perform EGR learning. Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. Yes 2. Turn the key switch “OFF”. Yes
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 6 Step 6
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-143 4021-143
DTC: 0606 DTC: 0606
CPU Abnormality CPU Abnormality

Drop of output power, starting not possible Drop of output power, starting not possible

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to “Service support check”. Is the action complete? Go to “Service support check”.
Step 2 Step 2
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Delete the diagnostic trouble code. Yes 1. Delete the diagnostic trouble code. Yes
2. See the service support DIAG (trouble diagnosis) 2. See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. No codes. No
3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0606 been 3. Turn the key switch “OFF” for at least 10 sec. Has a diagnostic trouble code: 0606 been
Go to diagnostic aid. Go to diagnostic aid.
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes

No Step 3 No Step 3
Is there an EMPS? Is there an EMPS?
Step 4 Step 4
1. Check the ECM software version. 1. Check the ECM software version.
Yes Yes
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
“How to Use EMPS”. “How to Use EMPS”.
Note: Note:
When ECM replacement or rewriting is performed, No When ECM replacement or rewriting is performed, No
perform EGR learning. Is the action complete? perform EGR learning. Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 5 Step 5
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. Is the action complete? perform EGR learning. Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. Yes 2. Turn the key switch “OFF”. Yes
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 6 Step 6
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-144 4021-144
DTC: 0611 DTC: 0611
Charge Circuit Abnormality (bank 1) Charge Circuit Abnormality (bank 1)

High engine vibration, unstable idling speed, High engine vibration, unstable idling speed,
drop of output power, revving problem, and drop of output power, revving problem, and
engine stalling are possible. engine stalling are possible.

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to “Service support check”. Is the action complete? Go to “Service support check”.

Yes Yes

Step 2 No Step 2 No
Go to step 12. Go to step 12.
Do you have a scan tool (KW communication)? Do you have a scan tool (KW communication)?
Step 3 Step 3
1. Check that communication is normal between all the 1. Check that communication is normal between all the
ECUs and the scan tool. Yes ECUs and the scan tool. Yes
2. Check that systems requiring programming are 2. Check that systems requiring programming are
operating normally. operating normally.
3. Confirm the diagnostic trouble code. No 3. Confirm the diagnostic trouble code. No
Has a diagnostic trouble code: 0611 been Has a diagnostic trouble code: 0611 been
detected? detected?

Step 4 Yes Step 4 Yes


1. Check whether the conditions below are present in Go to step 10. 1. Check whether the conditions below are present in Go to step 10.
the GND circuit between the ECM terminals (1, 3, 4, the GND circuit between the ECM terminals (1, 3, 4,
43, 62, and 81) and the ECM ground terminal (E2). 43, 62, and 81) and the ECM ground terminal (E2).
• Disconnection • Disconnection
• High resistance • High resistance
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. No detected. No
Was a problem detected? Was a problem detected?

Yes Yes
Step 5 Go to step 10. Step 5 Go to step 10.
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Disconnect the ECM ground terminal (E2). 2. Disconnect the ECM ground terminal (E2).
3. Inspect the ECM ground terminal (E2) for any 3. Inspect the ECM ground terminal (E2) for any
intermittent problems or connection problems. intermittent problems or connection problems.
4. Repair or replace as necessary if a problem is 4. Repair or replace as necessary if a problem is
detected. detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Step 6 Go to step 10. Step 6 Go to step 10.
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the ECM. 2. Remove the ECM.
3. Inspect the ECM terminals (1, 3, 4, 43, 62, 81) for 3. Inspect the ECM terminals (1, 3, 4, 43, 62, 81) for
4. any intermittent problems or connection problems. 4. any intermittent problems or connection problems.
5. Repair or replace as necessary if a problem is 5. Repair or replace as necessary if a problem is
detected. detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 10. Go to step 10.

No Step 7 No Step 7
Is there an EMPS? Is there an EMPS?

Yes Yes

Go to step 9. Go to step 8. Go to step 9. Go to step 8.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-145 4021-145

From step 7 From step 7

Step 8 Step 8
1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. No version is necessary. No
For details on checking the ECM and the rewriting, see Is the action complete? For details on checking the ECM and the rewriting, see Is the action complete?
“How to Use EMPS”. “How to Use EMPS”.
Note: Note:
When ECM replacement or rewriting is performed, Yes When ECM replacement or rewriting is performed, Yes
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 9 Step 9
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. Is the action complete? 1. Turn the key switch “ON”. Is the action complete?
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Yes Yes

Step 10 Step 10
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
3. Turn the key switch “OFF” for at least 10 sec. No Has a diagnostic trouble code: 0611 been 3. Turn the key switch “OFF” for at least 10 sec. No Has a diagnostic trouble code: 0611 been
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 11 Step 11
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.
Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

From step 2. From step 2.

No Step 12 No Step 12
Has a diagnostic trouble code: 0611 been Has a diagnostic trouble code: 0611 been
detected? detected?

Yes Yes
Go to step 4. Go to step 4.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-146 4021-146
Block diagram Block diagram
CONTROLLER A CONTROLLER A
“CAN COMMUNICATION” “CAN COMMUNICATION”

Preconditions when DTC is set Preconditions when DTC is set


• Main relay power supply voltage is 18 V or higher. • Main relay power supply voltage is 18 V or higher.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-147 4021-147
DTC: 0612 DTC: 0612
Charge Circuit Abnormality (bank 2) Charge Circuit Abnormality (bank 2)

High engine vibration, unstable idling speed, High engine vibration, unstable idling speed,
drop of output power, revving problem, and drop of output power, revving problem, and
engine stalling are possible. engine stalling are possible.

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to “Service support check”. Is the action complete? Go to “Service support check”.

Yes Yes

Step 2 No Step 2 No
Go to step 12. Go to step 12.
Do you have a scan tool (KW communication)? Do you have a scan tool (KW communication)?
Step 3 Step 3
1. Check that communication is normal between all the 1. Check that communication is normal between all the
ECUs and the scan tool. Yes ECUs and the scan tool. Yes
2. Check that systems requiring programming are 2. Check that systems requiring programming are
operating normally. operating normally.
3. Confirm the diagnostic trouble code. No 3. Confirm the diagnostic trouble code. No
Has a diagnostic trouble code: 0612 been Has a diagnostic trouble code: 0612 been
detected? detected?

Step 4 Yes Step 4 Yes


1. Check whether the conditions below are present in Go to step 10. 1. Check whether the conditions below are present in Go to step 10.
the GND circuit between the ECM terminals (1, 3, 4, the GND circuit between the ECM terminals (1, 3, 4,
43, 62, and 81) and the ECM ground terminal (E2). 43, 62, and 81) and the ECM ground terminal (E2).
• Disconnection • Disconnection
• High resistance • High resistance
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. No detected. No
Was a problem detected? Was a problem detected?

Yes Yes
Step 5 Go to step 10. Step 5 Go to step 10.
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Disconnect the ECM ground terminal (E2). 2. Disconnect the ECM ground terminal (E2).
3. Inspect the ECM ground terminal (E2) for any 3. Inspect the ECM ground terminal (E2) for any
intermittent problems or connection problems. intermittent problems or connection problems.
4. Repair or replace as necessary if a problem is 4. Repair or replace as necessary if a problem is
detected. detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Step 6 Go to step 10. Step 6 Go to step 10.
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the ECM. 2. Remove the ECM.
3. Inspect the ECM terminals (1, 3, 4, 43, 62, 81) for 3. Inspect the ECM terminals (1, 3, 4, 43, 62, 81) for
4. any intermittent problems or connection problems. 4. any intermittent problems or connection problems.
5. Repair or replace as necessary if a problem is 5. Repair or replace as necessary if a problem is
detected. detected.
No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 10. Go to step 10.

No Step 7 No Step 7
Is there an EMPS? Is there an EMPS?

Yes Yes

Go to step 9. Go to step 8. Go to step 9. Go to step 8.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-148 4021-148

From step 7 From step 7

Step 8 Step 8
1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. No version is necessary. No
For details on checking the ECM and the rewriting, see Was a problem detected? For details on checking the ECM and the rewriting, see Was a problem detected?
“How to Use EMPS”. “How to Use EMPS”.
Note: Note:
When ECM replacement or rewriting is performed, Yes When ECM replacement or rewriting is performed, Yes
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 9 Step 9
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. Is the action complete? 1. Turn the key switch “ON”. Is the action complete?
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. 3. Wait about 10 sec.
Yes Yes

Step 10 Step 10
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
3. Turn the key switch “OFF” for at least 10 sec. No Has a diagnostic trouble code: 0612 been 3. Turn the key switch “OFF” for at least 10 sec. No Has a diagnostic trouble code: 0612 been
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 11 Step 11
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.
Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

From step 2. From step 2.

No Step 12 No Step 12
Has a diagnostic trouble code: 0611 been Has a diagnostic trouble code: 0611 been
detected? detected?

Yes Yes
Go to step 4. Go to step 4.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-149 4021-149
Block diagram Block diagram
CONTROLLER A CONTROLLER A
“CAN COMMUNICATION” “CAN COMMUNICATION”

Preconditions when DTC is set Preconditions when DTC is set


• Main relay power supply voltage is 18 V or higher. • Main relay power supply voltage is 18 V or higher.

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DTC: 1093 DTC: 1093
No Pump Pressure Send No Pump Pressure Send

High engine vibration, unstable idling speed, High engine vibration, unstable idling speed,
drop of output power, revving problem, and drop of output power, revving problem, and
engine stalling are possible. engine stalling are possible.

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to “Service support check”. Is the action complete? Go to “Service support check”.
Step 2 Step 2
Inspect the fuel system. Yes Inspect the fuel system. Yes
1. In the high-pressure and low-pressure lines, inspect 1. In the high-pressure and low-pressure lines, inspect
for looseness in connections (fuel leaking), crushing, for looseness in connections (fuel leaking), crushing,
and clogging. Perform clogging inspection according and clogging. Perform clogging inspection according
to the procedure below. No to the procedure below. No
• Fuel filters (fuel main filter, fuel pre-filter) Is the fuel system normal? • Fuel filters (fuel main filter, fuel pre-filter) Is the fuel system normal?
• Fuel tank (pump strainer) • Fuel tank (pump strainer)
• Fuel system line Yes • Fuel system line Yes
2. Inspect whether there is any freezing or waxing within 2. Inspect whether there is any freezing or waxing within
the fuel line, fuel filter, and fuel tank (during cold the fuel line, fuel filter, and fuel tank (during cold
weather) weather)
3. Inspect whether any foreign matter is clogging the 3. Inspect whether any foreign matter is clogging the
feed pipe within the fuel tank. feed pipe within the fuel tank.

Step 3 Step 3
Charge fuel pump inspection Charge fuel pump inspection
1. See the Charge fuel pump inspection procedure and 1. See the Charge fuel pump inspection procedure and
inspect the charge fuel pump. inspect the charge fuel pump.
2. Perform repair or replacement for any locations where Is the action complete? 2. Perform repair or replacement for any locations where Is the action complete?
problems are found. problems are found.

Yes Yes

Step 4 Step 4
Check on the oil level gauge whether the oil level has Check on the oil level gauge whether the oil level has
risen, and check for diesel odors. risen, and check for diesel odors.
No No
Was a problem detected? Was a problem detected?

Yes Yes

Step 5 Step 5
Inspect the fuel pipe connections of each injector, and Inspect the fuel pipe connections of each injector, and
replace any injectors for which fuel leaks are confirmed. replace any injectors for which fuel leaks are confirmed.
Note: Note:
See the “Engine” section in the Service Manual for the Is the action complete? See the “Engine” section in the Service Manual for the Is the action complete?
work procedures. work procedures.

Yes Yes
Go to step 17. Go to step 17.

Step 6 No Step 6 No
Step 7 Go to step 20. Step 7 Go to step 20.
Inspect the injector. Do you have a scan tool (KW communication)? Inspect the injector. Do you have a scan tool (KW communication)?
1. Delete the diagnostic trouble code. See the service 1. Delete the diagnostic trouble code. See the service
support DIAG (trouble diagnosis) screen for Yes support DIAG (trouble diagnosis) screen for Yes
information on deleting diagnostic trouble codes. information on deleting diagnostic trouble codes.
2. Start the engine. 2. Start the engine.
3. Select “Actuator test” from the menu. No 3. Select “Actuator test” from the menu. No
4. Select “Injection stop at each injector” in “Common rail Was there a cylinder in which engine vibration 4. Select “Injection stop at each injector” in “Common rail Was there a cylinder in which engine vibration
system”. and engine noise did not change? system”. and engine noise did not change?
5. Press the “OFF” soft key to stop the injection of the 5. Press the “OFF” soft key to stop the injection of the
injectors for each cylinder one by one, and check the Yes injectors for each cylinder one by one, and check the Yes
change in the engine noise. Go to step 8. change in the engine noise. Go to step 8.

Go to step 9. Go to step 9.

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From step 7 From step 7

Step 8 Step 8
1. Replace the injectors of the cylinders for which the 1. Replace the injectors of the cylinders for which the
engine noise did not change in step 7. engine noise did not change in step 7.
Note: Note:
See the “Engine” section in the Service Manual for the Is the action complete? See the “Engine” section in the Service Manual for the Is the action complete?
work procedures. work procedures.

Yes Yes
Go to step 18. Go to step 18.

Step 9 From step 7 Step 9 From step 7


Inspect the common rail pressure. Inspect the common rail pressure.
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Use the scan tool to check the “Common rail 2. Use the scan tool to check the “Common rail
pressure” display in the data display. pressure” display in the data display.
3. Start and idle the engine. Reference value 3. Start and idle the engine. Reference value
4. Use the scan tool to check the “Common rail When engine is stopped: 4. Use the scan tool to check the “Common rail When engine is stopped:
pressure” display in the data display. -30MPa pressure” display in the data display. -30MPa
5. Quickly rev the engine about 5 times. During idling, revving: 5. Quickly rev the engine about 5 times. During idling, revving:
6. Use the scan tool to check the “Common rail ± 5 MPa 6. Use the scan tool to check the “Common rail ± 5 MPa
pressure” display in the data display. No For engine stopping, idling, and revving, is the pressure” display in the data display. No For engine stopping, idling, and revving, is the
corresponding “Common rail pressure” value corresponding “Common rail pressure” value
near the reference value? near the reference value?

Yes Yes
Go to step 16. Go to step 16.
Step 10 Step 10
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the common rail pressure sensor connector. 2. Remove the common rail pressure sensor connector.
3. Turn the key switch “ON”. 3. Turn the key switch “ON”.
4. Use the scan tool to check the “Common rail pressure 4. Use the scan tool to check the “Common rail pressure
sensor” display in the data display. No Reference value 4.8 V sensor” display in the data display. No Reference value 4.8 V
Is the “Common rail pressure sensor” Is the “Common rail pressure sensor”
value at or above the reference value? value at or above the reference value?

Yes Yes
Step 11 Go to step 15. Step 11 Go to step 15.
1. Use the breaker box or DMM to inspect whether there 1. Use the breaker box or DMM to inspect whether there
is a short circuit with another sensor's signal circuit in is a short circuit with another sensor's signal circuit in
the signal circuit between the common rail pressure the signal circuit between the common rail pressure
sensor and ECM. sensor and ECM.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
Yes Yes
Go to step 18. Go to step 18.

Step 13 Step 13
1. Check the ECM software version. 1. Check the ECM software version.
No Step 12 No Step 12
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. Is there an EMPS? version is necessary. Is there an EMPS?
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
“How to Use EMPS”. Yes “How to Use EMPS”. Yes
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] No [EGR learning method] No
1. Turn the key switch “ON”. Is the action complete? 1. Turn the key switch “ON”. Is the action complete?
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Yes 3. Wait about 10 sec. Yes
Go to step 18. Go to step 18.

Step 14 Step 14
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. Is the action complete? perform EGR learning. Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. Yes 2. Turn the key switch “OFF”. Yes
3. Wait about 10 sec. 3. Wait about 10 sec.
Go to step 18. Go to step 18.

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From step 10 From step 10

Step 15 Step 15
Replace the common rail (common rail pressure sensor). Replace the common rail (common rail pressure sensor).
Note: Note:
See the “Engine” section in the Service Manual for the See the “Engine” section in the Service Manual for the
work procedures. Is the action complete? work procedures. Is the action complete?

Yes Yes

Step 16 From step 9 Step 16 From step 9


1. Delete the diagnostic trouble code. 1. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
2. Start the engine. No Reference value 2. Start the engine. No Reference value
3. Select “Actuator test” from the menu. ± 5 MPa 3. Select “Actuator test” from the menu. ± 5 MPa
4. Select “Rail pressure control” in “Common rail Is the “Common rail pressure” 4. Select “Rail pressure control” in “Common rail Is the “Common rail pressure”
system”. value within the reference value range? system”. value within the reference value range?
5. Press the “UP” soft key and check the “Common rail 5. Press the “UP” soft key and check the “Common rail
pressure” value. Yes pressure” value. Yes

Step 17 Step 17
Replace the supply pump. Replace the supply pump.
Note: Note:
See the “Engine” section in the Service Manual for the See the “Engine” section in the Service Manual for the
work procedures. work procedures.
Is the action complete? Is the action complete?

Step 18 Yes Step 18 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble No Has a diagnostic trouble code: 1093 been screen for information on deleting diagnostic trouble No Has a diagnostic trouble code: 1093 been
codes. detected? codes. detected?
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when 4. Perform a test drive under the “Preconditions when
diagnostic trouble code is set”. Yes diagnostic trouble code is set”. Yes
Go to step 2. Go to step 2.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 19 Step 19
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.
Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Step 20 From step 6. Step 20 From step 6.


Use the injector checker to inspect the injectors. Use the injector checker to inspect the injectors.
For details on the injector checker usage method, see For details on the injector checker usage method, see
“How to use injector checker”. “How to use injector checker”.

No Was there a cylinder in which engine No Was there a cylinder in which engine
vibration and engine noise did not change? vibration and engine noise did not change?

Yes Yes
Go to step 8. Go to step 8.

Go to step 11. Go to step 11.

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Block diagram Block diagram

EGR MOTOR EGR MOTOR

EGR POSITION SENSOR EGR POSITION SENSOR

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 0090, 0192, 0193, 0201, 0202, 0203, 0204, 0611, 0612, 1093, 1095, 1261, 1262, and 1635 are not detected. • DTC: 0090, 0192, 0193, 0201, 0202, 0203, 0204, 0611, 0612, 1093, 1095, 1261, 1262, and 1635 are not detected.
• At least 1200 min-1 • At least 1200 min-1
Diagnostic aid Diagnostic aid
Possible causes include the following. Possible causes include the following.
• Injector internal trouble • Injector internal trouble
• Supply pump internal trouble • Supply pump internal trouble
• Fuel system line abnormality (fuel leaking, clogging, or crushing) • Fuel system line abnormality (fuel leaking, clogging, or crushing)
• Fuel filter abnormality (clogging) • Fuel filter abnormality (clogging)
• Fuel tank abnormality (clogging) • Fuel tank abnormality (clogging)
• Pressure limiter trouble (operation below regulated pressure, sealant deterioration) • Pressure limiter trouble (operation below regulated pressure, sealant deterioration)
• ECM trouble • ECM trouble
• Common rail pressure sensor trouble • Common rail pressure sensor trouble

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Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with other 82-GND 1 V or Short circuit with other 82-GND 1 V or
11 value mea- connector. 0V 11 value mea- connector. 0V
signal circuit 90-GND higher signal circuit 90-GND higher
surement • Key switch "ON" surement • Key switch "ON"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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DTC: 1095 DTC: 1095
Pressure Limiter Open Pressure Limiter Open

Drop of output power, hunting Drop of output power, hunting

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to “Service support check”. Is the action complete? Go to “Service support check”.
Step 2 Step 2
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Confirm and record the diagnostic trouble code. Yes 1. Confirm and record the diagnostic trouble code. Yes
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble No screen for information on deleting diagnostic trouble No
codes. Has a diagnostic trouble code: 1095 been codes. Has a diagnostic trouble code: 1095 been
See diagnostic aid. See diagnostic aid.
3. Check the fuel level and refill if necessary. detected? 3. Check the fuel level and refill if necessary. detected?
If the fuel is running low, air mixing in may cause If the fuel is running low, air mixing in may cause
diagnostic trouble code: 1095 to be detected. Yes diagnostic trouble code: 1095 to be detected. Yes
• If the air bleeding is inadequate, there is overshoot, • If the air bleeding is inadequate, there is overshoot,
the pressure exceeds 200 MPa, and a diagnostic the pressure exceeds 200 MPa, and a diagnostic
trouble code is detected. trouble code is detected.
Note: Note:
• Perform fuel air bleeding correctly according to the • Perform fuel air bleeding correctly according to the
procedure. procedure.
• See the “Engine” section in the Service Manual for • See the “Engine” section in the Service Manual for
the work procedures. the work procedures.
4. Perform fuel air bleeding. 4. Perform fuel air bleeding.
5. Quickly rev the engine about 5 times. 5. Quickly rev the engine about 5 times.
6. Confirm the diagnostic trouble code. 6. Confirm the diagnostic trouble code.

Step 3 Step 3
Narrow down the cause. Narrow down the cause.
1. Delete the diagnostic trouble code. 1. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) No See the service support DIAG (trouble diagnosis) No
screen for information on deleting diagnostic trouble Has a diagnostic trouble code: 1095 been screen for information on deleting diagnostic trouble Has a diagnostic trouble code: 1095 been
codes. detected? codes. detected?
2. Connect a separate line to the supply pump entry port 2. Connect a separate line to the supply pump entry port
and run the test.(At this time, replace the fuel hose Yes and run the test.(At this time, replace the fuel hose Yes
with a transparent hose and inspect visually that no Go to step 16. with a transparent hose and inspect visually that no Go to step 16.
air has gotten in.) air has gotten in.)
3. Confirm the diagnostic trouble code. 3. Confirm the diagnostic trouble code.

Step 4 Step 4
Inspect the fuel system using the following procedure. Inspect the fuel system using the following procedure.
1. In the high-pressure and low-pressure lines, inspect 1. In the high-pressure and low-pressure lines, inspect
for looseness in connections (fuel leaking), crushing, No for looseness in connections (fuel leaking), crushing, No
and clogging. Perform clogging inspection according Is the fuel system normal? and clogging. Perform clogging inspection according Is the fuel system normal?
to the procedure below. to the procedure below.
• Fuel filters (fuel main filter, fuel pre-filter) • Fuel filters (fuel main filter, fuel pre-filter)
Yes Yes
• Fuel tank (pump strainer) Go to step 6. • Fuel tank (pump strainer) Go to step 6.
• Fuel system line • Fuel system line
2. Inspect whether there is any freezing or waxing within 2. Inspect whether there is any freezing or waxing within
the fuel line, fuel filter, and fuel tank. (during cold the fuel line, fuel filter, and fuel tank. (during cold
weather) weather)
3. Inspect whether any foreign matter is clogging the 3. Inspect whether any foreign matter is clogging the
feed pipe within the fuel tank. feed pipe within the fuel tank.

Step 5 Step 5
Perform repair or replacement for any locations where Perform repair or replacement for any locations where
problems are found. problems are found.

Is the action complete? Is the action complete?

Yes Yes

Go to step 17. Go to step 17.

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From step 4 From step 4

Step 6 No Step 6 No
Go to step 20. Go to step 20.
Do you have a scan tool (KW communication)? Do you have a scan tool (KW communication)?

Step 7 Yes Step 7 Yes


Inspect the common rail pressure. Inspect the common rail pressure.
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Use the scan tool to check the “Common rail Reference value 2. Use the scan tool to check the “Common rail Reference value
pressure” display in the data display. When engine is stopped: pressure” display in the data display. When engine is stopped:
3. Start and idle the engine. -30 MPa 3. Start and idle the engine. -30 MPa
4. Use the scan tool to check the “Differential fuel rail During idling, revving: 4. Use the scan tool to check the “Differential fuel rail During idling, revving:
pressure” display in the data display. ± 5 MPa pressure” display in the data display. ± 5 MPa
5. Quickly rev the engine about 5 times. For engine stopping, idling, and revving, is the 5. Quickly rev the engine about 5 times. For engine stopping, idling, and revving, is the
6. Use the scan tool to check the “Differential fuel rail No 6. Use the scan tool to check the “Differential fuel rail No
corresponding “Differential fuel rail pressure” corresponding “Differential fuel rail pressure”
pressure” display in the data display. value near the reference value? pressure” display in the data display. value near the reference value?

Yes Yes
Go to step 14. Go to step 14.
Step 8 Step 8
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the common rail pressure sensor connector. 2. Remove the common rail pressure sensor connector.
3. Turn the key switch “ON”. 3. Turn the key switch “ON”.
4. Use the scan tool to check the “Common rail pressure 4. Use the scan tool to check the “Common rail pressure
sensor” display in the data display. No Reference value 0 V sensor” display in the data display. No Reference value 0 V
Is the “Common rail pressure sensor” Is the “Common rail pressure sensor”
value the reference value? value the reference value?

Yes Yes
Step 9 Go to step 13. Step 9 Go to step 13.
1. Use the breaker box or DMM to inspect whether there 1. Use the breaker box or DMM to inspect whether there
is a short circuit with another sensor's signal circuit in is a short circuit with another sensor's signal circuit in
the signal circuit between the common rail pressure the signal circuit between the common rail pressure
sensor and ECM. sensor and ECM.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
Yes Yes
Go to step 18. Go to step 18.

Step 11 Step 11
1. Check the ECM software version. 1. Check the ECM software version.
No Step 10 No Step 10
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. Is there an EMPS? version is necessary. Is there an EMPS?
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
“How to Use EMPS”. Yes “How to Use EMPS”. Yes
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] No [EGR learning method] No
1. Turn the key switch “ON”. Is the action complete? 1. Turn the key switch “ON”. Is the action complete?
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Yes 3. Wait about 10 sec. Yes
Go to step 13. Go to step 13.

Step 12 Step 12
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
Is the action complete? Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Yes 3. Wait about 10 sec. Yes

Go to step 13. Go to step 13.

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From step 12 From step 12

Step 13 Step 13
Replace the common rail (common rail pressure sensor). Replace the common rail (common rail pressure sensor).
Note: Note:
See the “Engine” section in the Service Manual for the See the “Engine” section in the Service Manual for the
work procedures. work procedures.
Is the action complete? Is the action complete?

Step 14 Yes Step 14 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Restore the actual machine. 1. Restore the actual machine.
2. Perform fuel air bleeding. From step 7 2. Perform fuel air bleeding. From step 7
3. Delete the diagnostic trouble code. 3. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
4. Perform a test drive under the “Preconditions when 4. Perform a test drive under the “Preconditions when
diagnostic trouble code is set”. Has a diagnostic trouble code: 1095 been No diagnostic trouble code is set”. Has a diagnostic trouble code: 1095 been No
Go to step 19. Go to step 19.
5. Confirm the diagnostic trouble code. detected? 5. Confirm the diagnostic trouble code. detected?

Yes Yes

Step 15 Step 15
1. Replace the common rail. 1. Replace the common rail.
Note: Note:
See the “Engine” section in the Service Manual for the See the “Engine” section in the Service Manual for the
work procedures. work procedures.
2. Perform fuel air bleeding. 2. Perform fuel air bleeding.
3. Delete the diagnostic trouble code. 3. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 1095 been No See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 1095 been No
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
4. Perform a test drive under the “Preconditions when 4. Perform a test drive under the “Preconditions when
Yes Yes
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 16 Step 16
1. Delete the diagnostic trouble code. 1. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
2. Start the engine. 2. Start the engine.
3. If you have a Tech2, go to step 3 below. 3. If you have a Tech2, go to step 3 below.
4. If you do not have a Tech2, go to step 17. No 4. If you do not have a Tech2, go to step 17. No
5. Select “Actuator test” from the menu. Reference value ± 5 MPa 5. Select “Actuator test” from the menu. Reference value ± 5 MPa
6. Select “Rail pressure control” in “Common rail Is the “Differential fuel rail pressure” value within 6. Select “Rail pressure control” in “Common rail Is the “Differential fuel rail pressure” value within
system”. the reference value range? system”. the reference value range?
7. Press the “UP” soft key and check the “Differential fuel 7. Press the “UP” soft key and check the “Differential fuel
rail pressure” value. Yes rail pressure” value. Yes

Step 17 Step 17
Replace the supply pump. Replace the supply pump.
Note: Note:
• After replacing parts, thoroughly perform air bleed- • After replacing parts, thoroughly perform air bleed-
ing.If the air bleeding is inadequate, fuel pressure Is the action complete? ing.If the air bleeding is inadequate, fuel pressure Is the action complete?
overshoot may cause diagnostic trouble code: 1095 overshoot may cause diagnostic trouble code: 1095
to be detected. to be detected.
• See the “Engine” section in the Service Manual for Yes • See the “Engine” section in the Service Manual for Yes
the work procedures. the work procedures.

Step 18 Step 18
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. No 2. Delete the diagnostic trouble code. No
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 1095 been See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 1095 been
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
3. Turn the key switch “OFF” for at least 10 sec. Yes 3. Turn the key switch “OFF” for at least 10 sec. Yes
4. Perform a test drive under the “Preconditions when Go to step 2. 4. Perform a test drive under the “Preconditions when Go to step 2.
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Go to step 19. Go to step 19.

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From step 18 From step 18

Step 19 Step 19
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.
Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

From step 6 From step 6

Step 20 Step 20
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the common rail pressure sensor connector. 2. Remove the common rail pressure sensor connector.
3. Turn the key switch “ON”. No 3. Turn the key switch “ON”. No
4. Connect the DMM between the GND and the signal Reference value 0 V 4. Connect the DMM between the GND and the signal Reference value 0 V
terminal of the common rail pressure sensor Is the DM display the reference value? terminal of the common rail pressure sensor Is the DM display the reference value?
connector. connector.
Note: Yes Note: Yes
If the DMM display is not the reference value, an ECM Go to step 13. If the DMM display is not the reference value, an ECM Go to step 13.
side wiring or ECM internal misconnection or short circuit side wiring or ECM internal misconnection or short circuit
is conceivable. is conceivable.
If the DMM display is the reference value, the ECM side If the DMM display is the reference value, the ECM side
wiring is normal. Go to step 9. wiring is normal. Go to step 9.

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4021-159 4021-159
Block diagram Block diagram

EGR MOTOR EGR MOTOR

EGR POSITION SENSOR EGR POSITION SENSOR

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 0192, 0193, 1095, 1630, and 1635 are not detected. • DTC: 0192, 0193, 1095, 1630, and 1635 are not detected.
• At least 50 min-1 • At least 50 min-1
Diagnostic aid Diagnostic aid
Possible causes include the following. Possible causes include the following.
• Air entering the high-pressure fuel line • Air entering the high-pressure fuel line
• Injector internal trouble • Injector internal trouble
• Supply pump internal trouble • Supply pump internal trouble
• Fuel system line abnormality (clogging) • Fuel system line abnormality (clogging)
• Fuel filter abnormality (temporary clogging due to waxing during low temperatures) • Fuel filter abnormality (temporary clogging due to waxing during low temperatures)
• Fuel tank abnormality (temporary clogging, air entering due to fuel deficiency, air entering due to expansion tank fuel line • Fuel tank abnormality (temporary clogging, air entering due to fuel deficiency, air entering due to expansion tank fuel line
conversion) conversion)
• Pressure limiter trouble (operation below regulated pressure, sealant deterioration) • Pressure limiter trouble (operation below regulated pressure, sealant deterioration)
• ECM trouble • ECM trouble
• Common rail pressure sensor trouble • Common rail pressure sensor trouble
• No fuel (lack of gas) • No fuel (lack of gas)

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4021-160 4021-160
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with other 82-GND 1 V or Short circuit with other 82-GND 1 V or
9 value mea- connector. 0V 9 value mea- connector. 0V
signal circuit 90-GND higher signal circuit 90-GND higher
surement • Key switch "ON" surement • Key switch "ON"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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4021-161 4021-161
DTC: 1112 DTC: 1112
Boost Temperature Sensor Abnormality (abnormally low voltage) Boost Temperature Sensor Abnormality (abnormally low voltage)

No effect on operation No effect on operation

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to “Service support check”. Is the action complete? Go to “Service support check”.

Yes Yes

Step 2 No Step 2 No
Go to step 14. Go to step 14.
Do you have a scan tool (KW communication)? Do you have a scan tool (KW communication)?
Step 3 Step 3
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Use the scan tool to check the “Boost temperature 2. Use the scan tool to check the “Boost temperature
sensor” display. sensor” display.

Reference value 0.1 V No Reference value 0.1 V No


Is the “Boost temperature sensor” value at or Go to diagnostic aid. Is the “Boost temperature sensor” value at or Go to diagnostic aid.
below the reference value? below the reference value?
Step 4 Step 4
Check the installation status of the boost temperature Yes Check the installation status of the boost temperature Yes
sensor connector, the ECM connector, and the sensor connector, the ECM connector, and the
intermediate connector. intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. No the installation of the connectors. No
2. Correct as necessary if a problem is detected. Was a problem detected? 2. Correct as necessary if a problem is detected. Was a problem detected?

Yes Yes
Go to step 12. Go to step 12.
Step 5 Step 5
1. Turn the key switch “OFF”. 1. Turn the key switch “OFF”.
2. Remove the boost temperature sensor connector. 2. Remove the boost temperature sensor connector.
3. Use a jumper cable to create a short circuit between 3. Use a jumper cable to create a short circuit between
the boost temperature sensor connector GND the boost temperature sensor connector GND
terminal and the signal terminal. No Reference value 4.8 V terminal and the signal terminal. No Reference value 4.8 V
4. Turn the key switch “ON”. Is the “Boost temperature” value at or above the 4. Turn the key switch “ON”. Is the “Boost temperature” value at or above the
5. Use the scan tool to check the “Boost temperature” reference value? 5. Use the scan tool to check the “Boost temperature” reference value?
display in the data display. display in the data display.
Yes Yes
Go to step 8. Go to step 8.

Step 6 Step 6
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the power supply conditions below are present in the power supply
circuit between the ECM and boost temperature circuit between the ECM and boost temperature
sensor. sensor.
See the Breaker Box Inspection Procedure. No See the Breaker Box Inspection Procedure. No
Was a problem detected? Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection If there is no breaker box, see the Inspection
procedures for sensors on actual machine. Yes procedures for sensors on actual machine. Yes
• Disconnection Go to step 12. • Disconnection Go to step 12.
• High resistance • High resistance
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 7 Step 7
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and boost temperature sensor. No between the ECM and boost temperature sensor. No
See the Breaker Box Inspection Procedure. Was a problem detected? See the Breaker Box Inspection Procedure. Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
Yes Yes
for sensors on actual machine. Go to step 12. for sensors on actual machine. Go to step 12.
• Short circuit with boost temperature sensor GND cir- • Short circuit with boost temperature sensor GND cir-
cuit cuit
• Short circuit with GND circuit • Short circuit with GND circuit
• Disconnection • Disconnection
• High resistance Go to step 9. • High resistance Go to step 9.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

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4021-162 4021-162

From step 5 From step 5

Step 8 Step 8
Replace the boost temperature sensor. Replace the boost temperature sensor.

Is the action complete? Is the action complete?

Yes Yes

From step 7 From step 7

Step 10 Step 10
1. Check the ECM software version. 1. Check the ECM software version.
No Step 9 No Step 9
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. Is there an EMPS? version is necessary. Is there an EMPS?
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
“How to Use EMPS”. Yes “How to Use EMPS”. Yes
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] No [EGR learning method] No
1. Turn the key switch ”ON”. Is the action complete? 1. Turn the key switch ”ON”. Is the action complete?
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Yes 3. Wait about 10 sec. Yes

Step 11 Step 11
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
2. Turn the key switch “OFF”. 2. Turn the key switch “OFF”.
3. Wait about 10 sec. Is the action complete? 3. Wait about 10 sec. Is the action complete?

Yes Yes

Step 12 Step 12
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
3. Turn the key switch “OFF” for at least 10 sec. No Has a diagnostic trouble code: 1112 been 3. Turn the key switch “OFF” for at least 10 sec. No Has a diagnostic trouble code: 1112 been
4. Perform a test drive under the “Preconditions when detected? 4. Perform a test drive under the “Preconditions when detected?
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 13 Step 13
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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4021-163 4021-163

From step 2 From step 2

Step 14 Step 14
1. Start the engine 1. Start the engine
2. Check the boost temperature display. 2. Check the boost temperature display.

Reference value 214 °C No Reference value 214 °C No


(error display value) Go to diagnostic aid. (error display value) Go to diagnostic aid.
Is the “Boost temperature” display showing the Is the “Boost temperature” display showing the
error display value? error display value?

Step 15 Yes Step 15 Yes


Check the installation status of the boost temperature Check the installation status of the boost temperature
sensor connector, the ECM connector, and the sensor connector, the ECM connector, and the
intermediate connector. intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. the installation of the connectors.
2. Correct as necessary if a problem is detected. No 2. Correct as necessary if a problem is detected. No
Was a problem detected? Was a problem detected?

Yes Yes
Step 16 Go to step 12. Step 16 Go to step 12.
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the power supply conditions below are present in the power supply
circuit between the ECM and boost temperature circuit between the ECM and boost temperature
sensor. sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
2. Repair as necessary if a problem is detected. Go to step 12. 2. Repair as necessary if a problem is detected. Go to step 12.

Step 17 Step 17
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the signal circuit conditions below are present in the signal circuit
between the ECM and boost temperature sensor. No between the ECM and boost temperature sensor. No
See the Breaker Box Inspection Procedure. Was a problem detected? See the Breaker Box Inspection Procedure. Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. Yes for sensors on actual machine. Yes
• Short circuit with boost temperature sensor GND cir- Go to step 12. • Short circuit with boost temperature sensor GND cir- Go to step 12.
cuit cuit
• Short circuit with GND circuit • Short circuit with GND circuit
• Disconnection • Disconnection
• High resistance Go to step 8. • High resistance Go to step 8.
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.

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4021-164 4021-164
Block diagram Block diagram

BOOST PRESS. SENSOR BOOST PRESS. SENSOR

BOOST TEMP. SENSOR BOOST TEMP. SENSOR

659) 659)

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1634 is not detected. • DTC: 1634 is not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-165 4021-165
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 74-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 74-Sensor connector 100 Ω or 10 M Ω or
6 measure- connector. 6 measure- connector.
high resistance signal terminal lower higher high resistance signal terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
Resistance • Remove the sensor Resistance • Remove the sensor
Short circuit with GND 74 -109 10 M Ω 100 Ω or Short circuit with GND 74 -109 10 M Ω 100 Ω or
measure- connector. measure- connector.
circuit/GND 74-GND or higher lower circuit/GND 74-GND or higher lower
ment • Key switch "OFF" ment • Key switch "OFF"
7 7
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 74-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 74-Sensor connector 100 Ω or 10 M Ω or
measure- connector. measure- connector.
high resistance GND terminal lower higher high resistance GND terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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4021-166 4021-166
DTC: 1113 DTC: 1113
Boost Temperature Sensor Abnormality (abnormally high voltage) Boost Temperature Sensor Abnormality (abnormally high voltage)

No effect on operation No effect on operation

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to “Service support check”. Is the action complete? Go to “Service support check”.

Yes Yes

Step 2 No Step 2 No
Go to step 14. Go to step 14.
Do you have a scan tool (KW communication)? Do you have a scan tool (KW communication)?
Step 3 Step 3
1. Turn the key switch “ON”. 1. Turn the key switch “ON”.
Yes Yes
2. Use the scan tool to check the “Boost temperature 2. Use the scan tool to check the “Boost temperature
sensor” display in the data display. sensor” display in the data display.

Reference value 4.95 V No Reference value 4.95 V No


Is the “Boost temperature sensor” value at or Go to diagnostic aid. Is the “Boost temperature sensor” value at or Go to diagnostic aid.
above the reference value? above the reference value?
Step 4 Step 4
Check the installation status of the boost temperature Yes Check the installation status of the boost temperature Yes
sensor connector, the ECM connector, and the sensor connector, the ECM connector, and the
intermediate connector. intermediate connector.
1. Inspect whether there is any backlash or looseness in 1. Inspect whether there is any backlash or looseness in
the installation of the connectors. No the installation of the connectors. No
2. Correct as necessary if a problem is detected. Was a problem detected? 2. Correct as necessary if a problem is detected. Was a problem detected?

Yes Yes
Go to step 12. Go to step 12.
Step 5 Step 5
1. Use the breaker box or DMM to check whether a short 1. Use the breaker box or DMM to check whether a short
circuit with the power supply circuit or ignition power circuit with the power supply circuit or ignition power
supply circuit is present in the signal circuit between supply circuit is present in the signal circuit between
the ECM and boost temperature sensor. the ECM and boost temperature sensor.
See the Breaker Box Inspection Procedure. No See the Breaker Box Inspection Procedure. No
Note: Was a problem detected? Note: Was a problem detected?
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
Important: Yes Important: Yes
If the boost temperature sensor circuit is short-circuited to Go to step 11. If the boost temperature sensor circuit is short-circuited to Go to step 11.
the power supply circuit, there may be sensors that are the power supply circuit, there may be sensors that are
damaged. damaged.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 6 Step 6
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the GND circuit conditions below are present in the GND circuit
between the ECM and boost temperature sensor. between the ECM and boost temperature sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection Was a problem detected? Go to step 8. If there is no breaker box, see the Inspection Was a problem detected? Go to step 8.
procedures for sensors on actual machine. procedures for sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
Go to step 11. Go to step 11.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

From step 15 From step 15

Step 7 Step 7
Replace the boost temperature sensor. Replace the boost temperature sensor.

Is the action complete? Is the action complete?

Yes Yes
Go to step 11. Go to step 11.

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4021-167 4021-167

Step 9 Step 9
1. Check the ECM software version. 1. Check the ECM software version.
From steps 6 From steps 6
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
"How to Use EMPS". No "How to Use EMPS". No
Step 8 Step 8
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] Yes [EGR learning method] Yes
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 10 Step 10
Replace the ECM. Yes Replace the ECM. Yes
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Step 11 Yes Step 11 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
3. Turn the key switch "OFF" for at least 10 sec. No Has a diagnostic trouble code: 0238 been 3. Turn the key switch "OFF" for at least 10 sec. No Has a diagnostic trouble code: 0238 been
4. Perform a test drive under the "Preconditions when detected? 4. Perform a test drive under the "Preconditions when detected?
diagnostic trouble code is set". diagnostic trouble code is set".
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 12 Step 12
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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4021-168 4021-168

From step 2 From step 2

Step 13 Step 13
1. Start the engine. 1. Start the engine.
2. Check the boost temperature display. 2. Check the boost temperature display.

Reference value Reference value


214 °C No 214 °C No
(error display value) Go to diagnostic aid. (error display value) Go to diagnostic aid.
Is the "Boost temperature" display showing the Is the "Boost temperature" display showing the
Step 14 Step 14
error display value? error display value?
Check the installation status of the boost temperature Check the installation status of the boost temperature
sensor connector, the ECM connector, and the sensor connector, the ECM connector, and the
intermediate connector. Yes intermediate connector. Yes
1. Inspect whether there is any backlash or ooseness in 1. Inspect whether there is any backlash or ooseness in
the installation of the connectors. the installation of the connectors.
2. Correct as necessary if a problem is detected. 2. Correct as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?

Yes Yes
Go to step 11. Go to step 11.
Step 15 Step 15
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the GND circuit conditions below are present in the GND circuit
between the ECM and boost temperature sensor. between the ECM and boost temperature sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
Go to step 11. Go to step 11.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Go to step 7. Go to step 7.

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4021-169 4021-169
Block diagram Block diagram

BOOST PRESS. SENSOR BOOST PRESS. SENSOR

BOOST TEMP. SENSOR BOOST TEMP. SENSOR

659) 659)

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1634 is not detected. • DTC: 1634 is not detected.
• Engine coolant temperature is 50C or higher. • Engine coolant temperature is 50C or higher.
• At least 5 min. passed after start. • At least 5 min. passed after start.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Breaker box inspection procedure Breaker box inspection procedure


For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with power 18 V or Short circuit with power 18 V or
5 value mea- connector. 74-GND 0V 5 value mea- connector. 74-GND 0V
supply circuit higher supply circuit higher
surement • Key switch "ON" surement • Key switch "ON"
Resistance • Remove the sensor Resistance • Remove the sensor
Disconnection/ 109-Sensor connector 100 Ω or 10 M Ω or Disconnection/ 109-Sensor connector 100 Ω or 10 M Ω or
6 measure- connector. 6 measure- connector.
high resistance GND terminal lower higher high resistance GND terminal lower higher
ment • Key switch "OFF" ment • Key switch "OFF"

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4021-170 4021-170
DTC: 1173 DTC: 1173
Overheat Overheat

If the coolant temperature exceeds 100 °C If the coolant temperature exceeds 100 °C
during overheating or the output power drops, during overheating or the output power drops,
the fuel flow is restricted. the fuel flow is restricted.

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to "Service support check". Is the action complete? Go to "Service support check".

Step 2 Yes Step 2 Yes


1. Start the engine. 1. Start the engine.
2. Confirm the diagnostic trouble code. 2. Confirm the diagnostic trouble code.

No Has a diagnostic trouble code: 0088 or 1093 No Has a diagnostic trouble code: 0088 or 1093
been detected? been detected?

Yes Go to diagnosis for the detected Yes Go to diagnosis for the detected
diagnostic trouble code. diagnostic trouble code.

Step 4 Step 4
Turn the key switch "OFF". No Turn the key switch "OFF". No
Remove the ECT (engine coolant temperature) sensor Step 3 Remove the ECT (engine coolant temperature) sensor Step 3
Go to step 14. Go to step 14.
connector. Do you have a scan tool (KW communication)? connector. Do you have a scan tool (KW communication)?
Turn the key switch "ON". Turn the key switch "ON".
Use the scan tool to check the "ECT sensor" display in Yes Use the scan tool to check the "ECT sensor" display in Yes
the data display. the data display.

No Reference value No Reference value


4.9 V/- 40 °C 4.9 V/- 40 °C
Is the "ECT sensor" value at or above the Is the "ECT sensor" value at or above the
Step 5 reference value? Step 5 reference value?
1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
Yes Yes
short circuit with another sensor's signal circuit is short circuit with another sensor's signal circuit is
present in the signal circuit between the ECT sensor present in the signal circuit between the ECT sensor
and ECM. and ECM.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.
2. Repair as necessary if a problem is detected. No 2. Repair as necessary if a problem is detected. No
Was a problem detected? Go to step 10. Was a problem detected? Go to step 10.

Yes Yes
Go to step 13. Go to step 13.
Step 6 Step 6
1. Inspect to see if the engine coolant is too low. 1. Inspect to see if the engine coolant is too low.
2. If the engine coolant is too low, refill it. 2. If the engine coolant is too low, refill it.
3. Delete the diagnostic trouble code. 3. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
4. Turn the key switch "OFF" for at least 10 sec. 4. Turn the key switch "OFF" for at least 10 sec.
5. Start the engine and check the diagnostic trouble 5. Start the engine and check the diagnostic trouble
code. Has a diagnostic trouble code: 1173 been No code. Has a diagnostic trouble code: 1173 been No
Go to step 13. Go to step 13.
detected? detected?

Step 7 Yes Step 7 Yes


1. Inspect for the following mechanical defects. 1. Inspect for the following mechanical defects.
(See "Cooling system" in the "Engine" section in the (See "Cooling system" in the "Engine" section in the
Service Manual.) Service Manual.)
• Radiator clogged No • Radiator clogged No
Was a problem detected? Was a problem detected?
• Radiator cap defect • Radiator cap defect
• Fan belt looseness • Fan belt looseness
• Thermostat defect Yes • Thermostat defect Yes
• Water pump defect Go to step 13. • Water pump defect Go to step 13.
• Cylinder head gasket defect • Cylinder head gasket defect
2. Replace or adjust as necessary if a problem is 2. Replace or adjust as necessary if a problem is
detected. detected.

Go to step 8. Go to step 8.

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4021-171 4021-171

From step 7 From step 7

Step 8 Step 8
Replace the ECT sensor. Replace the ECT sensor.

Is the action complete? Is the action complete?

Step 9 Yes Step 9 Yes


Recheck the diagnostic trouble code. Go to step 13. Recheck the diagnostic trouble code. Go to step 13.
1. Delete the diagnostic trouble code. 1. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble From step 11 screen for information on deleting diagnostic trouble From step 11
codes. codes.
2. Turn the key switch "OFF" for at least 10 sec. 2. Turn the key switch "OFF" for at least 10 sec.
3. Perform a test drive under the "Preconditions when 3. Perform a test drive under the "Preconditions when
diagnostic trouble code is set". diagnostic trouble code is set".
4. Confirm the diagnostic trouble code. Has a diagnostic trouble code: 1173 been 4. Confirm the diagnostic trouble code. Has a diagnostic trouble code: 1173 been
Go to diagnostic aid. Go to diagnostic aid.
detected? detected?

Yes Yes

Step 11 Step 11
1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
"How to Use EMPS". No "How to Use EMPS". No
Step 10 Step 10
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
EGR learning method Yes EGR learning method Yes
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 12 Step 12
Replace the ECM. Yes Replace the ECM. Yes
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
EGR learning method EGR learning method
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Yes Yes

Step 13 Step 13
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Step 14 From step 3 Step 14 From step 3


1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the ECT sensor connector. 2. Remove the ECT sensor connector.
3. Turn the key switch "ON". 3. Turn the key switch "ON".
4. Check the "Engine coolant temperature" display. 4. Check the "Engine coolant temperature" display.

Reference value Reference value


-40 °C -40 °C
No No
Is the "Engine coolant temperature" display at or Go to step 5. Is the "Engine coolant temperature" display at or Go to step 5.
above the reference value? above the reference value?

Yes Yes

Go to step 6. Go to step 6.

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4021-172 4021-172
Block diagram Block diagram

OIL PRESS. SENSOR OIL PRESS. SENSOR

WATER TEMP. SENSOR WATER TEMP. SENSOR

FUEL TEMP. SENSOR FUEL TEMP. SENSOR

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 0117, 0118, 1630, and 1633 are not detected. • DTC: 0117, 0118, 1630, and 1633 are not detected.
• Engine running • Engine running

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4021-173 4021-173
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Breaker box inspection procedure Breaker box inspection procedure


For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove the sensor Voltage • Remove the sensor
Short circuit with other 1 V or Short circuit with other 1 V or
5 value mea- connector. 84-GND 0V 5 value mea- connector. 84-GND 0V
signal circuit higher signal circuit higher
surement • Key switch "ON" surement • Key switch "ON"

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

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4021-174 4021-174
DTC: 1261 DTC: 1261
Injector Common 1 Drive System Abnormality Injector Common 1 Drive System Abnormality

High engine vibration, unstable idling speed, drop of High engine vibration, unstable idling speed, drop of
output power, revving problem, and engine stalling output power, revving problem, and engine stalling
are possible. are possible.

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to "Service support check". Is the action complete? Go to "Service support check".
Step 2 Step 2
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the ECM side harness connector from the Yes 2. Remove the ECM side harness connector from the Yes
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Connect the DMM between the GND and the 3. Connect the DMM between the GND and the
injector power supply 1 circuit. injector power supply 1 circuit.
4. Turn the key switch "ON". 4. Turn the key switch "ON".
CN.A3 female side No. 1 No Reference value CN.A3 female side No. 1 No Reference value
7.0 V 7.0 V
Is the DMM display at or above the reference value? Is the DMM display at or above the reference value?

Step 3 Yes Step 3 Yes


1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the ECM side harness connector from the 2. Remove the ECM side harness connector from the
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Measure the resistance between the injector 3. Measure the resistance between the injector
harness connector terminals. harness connector terminals.
CN.A3 male side No.1 and No. 4 Reference value No CN.A3 male side No.1 and No. 4 Reference value No
1.0 Ω Go to step 18. 1.0 Ω Go to step 18.
Is the resistance at or below the reference value? Is the resistance at or below the reference value?

Step 4 Yes Step 4 Yes


Check the installation status of the injector harness Check the installation status of the injector harness
connector, ECM connector, and intermediate connector, ECM connector, and intermediate
connector. connector.
1. Inspect whether there is any backlash or 1. Inspect whether there is any backlash or
looseness in the installation of the connectors. looseness in the installation of the connectors.
2. Correct as necessary if a problem is detected. 2. Correct as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?
Step 5 Step 5
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the injector power Yes conditions below are present in the injector power Yes
supply 1 circuit. Go to step 23. supply 1 circuit. Go to step 23.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection If there is no breaker box, see the Inspection
procedures for sensors on actual machine. procedures for sensors on actual machine.
• Disconnection • Disconnection
• High resistance No • High resistance No
• Short circuit with GND Was a problem detected? Go to step 20. • Short circuit with GND Was a problem detected? Go to step 20.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Yes Yes
Go to step 23. Go to step 23.
Step 6 Step 6
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the ECM side harness connector from the 2. Remove the ECM side harness connector from the
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Measure the resistance between the GND and the 3. Measure the resistance between the GND and the
No. 2 cylinder injector drive circuit. No. 2 cylinder injector drive circuit.
CN.A3 male side No. 5 CN.A3 male side No. 5

Reference value No Reference value No


10 MΩ Go to step 8. 10 MΩ Go to step 8.
Step 7 Is the resistance at or above the reference value? Step 7 Is the resistance at or above the reference value?
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the ECM side harness connector from the Yes 2. Remove the ECM side harness connector from the Yes
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Measure the resistance between the GND and the 3. Measure the resistance between the GND and the
No. 2 cylinder injector drive circuit. No. 2 cylinder injector drive circuit.
CN.A3 male side No. 8 Reference value No CN.A3 male side No. 8 Reference value No
10 MΩ Go to step 9. 10 MΩ Go to step 9.
Is the resistance at or above the reference value? Is the resistance at or above the reference value?

Yes Yes

Go to step 10. Go to step 10.

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4021-175 4021-175

From step 6 From step 6


Step 8 Step 8
1. Use the breaker box or DMM to check whether a short 1. Use the breaker box or DMM to check whether a short
circuit with GND is present in the No. 1 cylinder injector circuit with GND is present in the No. 1 cylinder injector
drive circuit between the ECM and the intermediate drive circuit between the ECM and the intermediate
connector (CN.A3). connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. sensors on actual machine.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

No No
Was a problem detected? Go to step 20. Was a problem detected? Go to step 20.

Yes Yes
Go to step 23. Go to step 23.

From step 7 From step 7


Step 9 Step 9
1. Use the breaker box or DMM to check whether a short 1. Use the breaker box or DMM to check whether a short
circuit with GND is present in the No. 4 cylinder injector circuit with GND is present in the No. 4 cylinder injector
drive circuit between the ECM and the intermediate drive circuit between the ECM and the intermediate
connector (CN.A3). connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20. If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20.
sensors on actual machine. sensors on actual machine.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
Yes Yes
Go to step 23. Go to step 23.

From step 7 From step 7


Step 10 Step 10
1. Remove the cylinder head cover. 1. Remove the cylinder head cover.
2. Inspect the installation status of the injector harness. 2. Inspect the installation status of the injector harness.
3. Correct as necessary if a problem is detected. 3. Correct as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?

Yes Yes
Step 11 Go to step 23. Step 11 Go to step 23.
1. Remove the injector or the injector harness. 1. Remove the injector or the injector harness.
No. 1 cylinder, No. 4 cylinder No. 1 cylinder, No. 4 cylinder
2. Measure the resistance between the GND and each injector 2. Measure the resistance between the GND and each injector
terminal. terminal.

Reference value No Reference value No


10 MΩ Go to step 19. 10 MΩ Go to step 19.
Is the resistance at or above the reference value? Is the resistance at or above the reference value?
Step 14 Step 14
1. Turn the key switch "OFF". Yes 1. Turn the key switch "OFF". Yes
2. Remove the injector side harness connector from the 2. Remove the injector side harness connector from the
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Connect the DMM between the GND and the No. 1 cylinder No Reference value 3. Connect the DMM between the GND and the No. 1 cylinder No Reference value
injector drive circuit. 0V injector drive circuit. 0V
CN.A3 female side No. 5 Is the DMM display the reference value? CN.A3 female side No. 5 Is the DMM display the reference value?
4. Turn the key switch "ON". 4. Turn the key switch "ON".
Yes Yes
Go to step 15. Go to step 15.

Go to step 13. Go to step 13.

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4021-176 4021-176

Step 13 Go to step 12. Step 13 Go to step 12.


1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the injector side harness connector from the 2. Remove the injector side harness connector from the
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Connect the DMM between the GND and the No. 4 cylinder 3. Connect the DMM between the GND and the No. 4 cylinder
injector drive circuit. injector drive circuit.
CN.A3 female side No. 8. CN.A3 female side No. 8.
4. Turn the key switch "ON". No Reference value 4. Turn the key switch "ON". No Reference value
0V 0V
Is the DMM display at or above the reference value? Is the DMM display at or above the reference value?

Step 14 Yes Step 14 Yes


1. Turn the key switch "OFF". Go to step 16. 1. Turn the key switch "OFF". Go to step 16.
2. Remove the injector side harness connector from the 2. Remove the injector side harness connector from the
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Connect the DMM between the GND and the injector power 3. Connect the DMM between the GND and the injector power
supply 1 circuit. supply 1 circuit.
CN.A3 female side No. 1 CN.A3 female side No. 1
4. Turn the key switch "ON". 4. Turn the key switch "ON".

Reference value No Reference value No


7.0 V Go to step 21. 7.0 V Go to step 21.
Is the DMM display at or below the reference value? Is the DMM display at or below the reference value?

Yes Yes
Go to step 22. Go to step 22.

Go to step 12. Go to step 12.


Step 15 Step 15
1. Use the breaker box or DMM to check whether a short 1. Use the breaker box or DMM to check whether a short
circuit with the power supply circuit or ignition power supply circuit with the power supply circuit or ignition power supply
circuit is present in the No. 1 cylinder injector drive circuit circuit is present in the No. 1 cylinder injector drive circuit
between the ECM and the intermediate connector (CN.A3). between the ECM and the intermediate connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20. If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20.
sensors on actual machine. sensors on actual machine.
2. Correct as necessary if a problem is detected. 2. Correct as necessary if a problem is detected.
Yes Yes
Go to step 23. Go to step 23.

Go to step 13. Go to step 13.


Step 16 Step 16
1. Use the breaker box or DMM to check whether a short 1. Use the breaker box or DMM to check whether a short
circuit with the power supply circuit or ignition power supply circuit with the power supply circuit or ignition power supply
circuit is present in the No. 4 cylinder injector drive circuit circuit is present in the No. 4 cylinder injector drive circuit
between the ECM and the intermediate connector (CN.A3). between the ECM and the intermediate connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20. If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20.
sensors on actual machine. sensors on actual machine.
2. Correct as necessary if a problem is detected. 2. Correct as necessary if a problem is detected.
Yes Yes
Go to step 23. Go to step 23.

Go to step 14 Go to step 14
Step 17 Step 17
1. Use the breaker box or DMM to check whether a short 1. Use the breaker box or DMM to check whether a short
circuit with the power supply circuit or ignition power supply circuit with the power supply circuit or ignition power supply
circuit is present in the injector power supply 1 circuit circuit is present in the injector power supply 1 circuit
between the ECM and the intermediate connector (CN.A3). between the ECM and the intermediate connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20. If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20.
sensors on actual machine. sensors on actual machine.
2. Correct as necessary if a problem is detected. 2. Correct as necessary if a problem is detected.
Yes Yes
Go to step 23. Go to step 23.

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4021-177 4021-177

From step 14 From step 14

Step 18 Step 18
Replace the injector harness. Replace the injector harness.

Is the action complete? Is the action complete?

Yes Yes
Go to step 23. Go to step 23.

Step 19 From step 11 Step 19 From step 11


Replace the injector. Replace the injector.
Note: Note:
See the "Engine" section in the Service Manual for the See the "Engine" section in the Service Manual for the
work procedures. work procedures.

Is the action complete? Is the action complete?

Yes Yes
Go to step 23. Go to step 23.

Step 21 Step 21
1. Check the ECM software version. 1. Check the ECM software version.
From steps 5, 8, 9, 15 From steps 5, 8, 9, 15
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
"How to Use EMPS". No "How to Use EMPS". No
Step 20 Step 20
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] Yes [EGR learning method] Yes
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 22 Step 22
Replace the ECM. Yes Replace the ECM. Yes
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Step 23 Yes Step 23 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
3. Turn the key switch "OFF" for at least 10 sec. No Has a diagnostic trouble code: 1261 been 3. Turn the key switch "OFF" for at least 10 sec. No Has a diagnostic trouble code: 1261 been
4. Perform a test drive under the "Preconditions when detected? 4. Perform a test drive under the "Preconditions when detected?
diagnostic trouble code is set". diagnostic trouble code is set".
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 28 Step 28
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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Block diagram Block diagram

OIL PRESS. SENSOR OIL PRESS. SENSOR

WATER TEMP. SENSOR WATER TEMP. SENSOR

FUEL TEMP. SENSOR FUEL TEMP. SENSOR

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Main relay power supply voltage is 18 V or higher. • Main relay power supply voltage is 18 V or higher.
• 70 min-1 • 70 min-1
• DTC: 0201, 0204, 0611, and 1261 are not detected. • DTC: 0201, 0204, 0611, and 1261 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-179 4021-179
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
• Remove the ECM-side • Remove the ECM-side
Resistance harness connector Resistance harness connector
Disconnection/ 121-Female-side termi- 100 Ω or 10 M Ω or Disconnection/ 121-Female-side termi- 100 Ω or 10 M Ω or
measure- from the intermediate measure- from the intermediate
high resistance nal (CN. A3 No. 1) lower higher high resistance nal (CN. A3 No. 1) lower higher
ment connector. ment connector.
• Key switch "OFF" • Key switch "OFF"
5 5
• Remove the ECM-side • Remove the ECM-side
Resistance harness connector Resistance harness connector
from the intermediate 10 M Ω 100 Ω or from the intermediate 10 M Ω 100 Ω or
Short circuit with GND measure- 121-GND Short circuit with GND measure- 121-GND
connector. or higher lower connector. or higher lower
ment ment
• Key switch "OFF" • Key switch "OFF"
• Remove the ECM-side • Remove the ECM-side
Resistance harness connector Resistance harness connector
10 M Ω 100 Ω or 10 M Ω 100 Ω or
8 Short circuit with GND measure- from the intermediate 119-GND 8 Short circuit with GND measure- from the intermediate 119-GND
or higher lower or higher lower
ment connector. ment connector.
• Key switch "OFF" • Key switch "OFF"
• Remove the ECM-side • Remove the ECM-side
Resistance harness connector Resistance harness connector
from the intermediate 10 M Ω 100 Ω or from the intermediate 10 M Ω 100 Ω or
9 Short circuit with GND measure- 114-GND 9 Short circuit with GND measure- 114-GND
connector. or higher lower connector. or higher lower
ment ment
• Key switch "OFF" • Key switch "OFF"
• Remove the ECM-side • Remove the ECM-side
Voltage harness connector Voltage harness connector
Short circuit with power 18 V or Short circuit with power 18 V or
15 value mea- from the intermediate 119-GND 0V 15 value mea- from the intermediate 119-GND 0V
supply circuit higher supply circuit higher
surement connector. surement connector.
• Key switch "OFF" • Key switch "OFF"
• Remove the ECM-side • Remove the ECM-side
Voltage harness connector Voltage harness connector
Short circuit with power from the intermediate 18 V or Short circuit with power from the intermediate 18 V or
16 value mea- 114-GND 0V 16 value mea- 114-GND 0V
supply circuit higher supply circuit higher
surement connector. surement connector.
• Key switch "OFF" • Key switch "OFF"
• Remove the ECM-side • Remove the ECM-side
Voltage harness connector Voltage harness connector
Short circuit with power 18 V or Short circuit with power 18 V or
17 value mea- from the intermediate 121-GND 0V 17 value mea- from the intermediate 121-GND 0V
supply circuit higher supply circuit higher
surement connector. surement connector.
• Key switch "OFF" • Key switch "OFF"

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4021-180 4021-180
DTC: 1262 DTC: 1262
Injector Common 2 Drive System Abnormality Injector Common 2 Drive System Abnormality

High engine vibration, unstable idling speed, drop of High engine vibration, unstable idling speed, drop of
output power, revving problem, and engine stalling output power, revving problem, and engine stalling
are possible. are possible.

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to "Service support check". Is the action complete? Go to "Service support check".
Step 2 Step 2
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the ECM side harness connector from the Yes 2. Remove the ECM side harness connector from the Yes
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Connect the DMM between the GND and the 3. Connect the DMM between the GND and the
injector power supply 1 circuit. injector power supply 1 circuit.
4. Turn the key switch "ON". 4. Turn the key switch "ON".
CN.A3 female side No. 3 No Reference value CN.A3 female side No. 3 No Reference value
7.0 V 7.0 V
Is the DMM display at or above the reference value? Is the DMM display at or above the reference value?

Step 3 Yes Step 3 Yes


1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the ECM side harness connector from the 2. Remove the ECM side harness connector from the
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Measure the resistance between the injector 3. Measure the resistance between the injector
harness connector terminals. harness connector terminals.
CN.A3 male side No. 3 and No. 2 Reference value No CN.A3 male side No. 3 and No. 2 Reference value No
1.0 Ω Go to step 18. 1.0 Ω Go to step 18.
Is the resistance at or below the reference value? Is the resistance at or below the reference value?

Step 4 Yes Step 4 Yes


Check the installation status of the injector harness Check the installation status of the injector harness
connector, ECM connector, and intermediate connector, ECM connector, and intermediate
connector. connector.
1. Inspect whether there is any backlash or 1. Inspect whether there is any backlash or
looseness in the installation of the connectors. looseness in the installation of the connectors.
2. Correct as necessary if a problem is detected. 2. Correct as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?
Step 5 Step 5
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the injector power Yes conditions below are present in the injector power Yes
supply 2 circuit. Go to step 23. supply 2 circuit. Go to step 23.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection If there is no breaker box, see the Inspection
procedures for sensors on actual machine. procedures for sensors on actual machine.
• Disconnection • Disconnection
• High resistance No • High resistance No
• Short circuit with GND Was a problem detected? Go to step 20. • Short circuit with GND Was a problem detected? Go to step 20.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Yes Yes
Go to step 23. Go to step 23.
Step 6 Step 6
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the ECM side harness connector from the 2. Remove the ECM side harness connector from the
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Measure the resistance between the GND and the 3. Measure the resistance between the GND and the
No. 2 cylinder injector drive circuit. No. 2 cylinder injector drive circuit.
CN.A3 male side No. 7 CN.A3 male side No. 7

Reference value No Reference value No


10 MΩ Go to step 8. 10 MΩ Go to step 8.
Step 7 Is the resistance at or above the reference value? Step 7 Is the resistance at or above the reference value?
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the ECM side harness connector from the Yes 2. Remove the ECM side harness connector from the Yes
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Measure the resistance between the GND and the 3. Measure the resistance between the GND and the
No. 3 cylinder injector drive circuit. No. 3 cylinder injector drive circuit.
CN.A3 male side No. 6 Reference value No CN.A3 male side No. 6 Reference value No
10 MΩ Go to step 9. 10 MΩ Go to step 9.
Is the resistance at or above the reference value? Is the resistance at or above the reference value?

Yes Yes

Go to step 10. Go to step 10.

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From step 6 From step 6


Step 8 Step 8
1. Use the breaker box or DMM to check whether a short 1. Use the breaker box or DMM to check whether a short
circuit with GND is present in the No. 2 cylinder injector circuit with GND is present in the No. 2 cylinder injector
drive circuit between the ECM and the intermediate drive circuit between the ECM and the intermediate
connector (CN.A3). connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. sensors on actual machine.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

No No
Was a problem detected? Go to step 20. Was a problem detected? Go to step 20.

Yes Yes
Go to step 23. Go to step 23.

From step 7 From step 7


Step 9 Step 9
1. Use the breaker box or DMM to check whether a short 1. Use the breaker box or DMM to check whether a short
circuit with GND is present in the No. 3 cylinder injector circuit with GND is present in the No. 3 cylinder injector
drive circuit between the ECM and the intermediate drive circuit between the ECM and the intermediate
connector (CN.A3). connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20. If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20.
sensors on actual machine. sensors on actual machine.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
Yes Yes
Go to step 23. Go to step 23.

From step 7 From step 7


Step 10 Step 10
1. Remove the cylinder head cover. 1. Remove the cylinder head cover.
2. Inspect the installation status of the injector harness. 2. Inspect the installation status of the injector harness.
3. Correct as necessary if a problem is detected. 3. Correct as necessary if a problem is detected.

No No
Was a problem detected? Was a problem detected?

Yes Yes
Step 11 Go to step 23. Step 11 Go to step 23.
1. Remove the injector or the injector harness. 1. Remove the injector or the injector harness.
No. 2 cylinder, No. 3 cylinder No. 2 cylinder, No. 3 cylinder
2. Measure the resistance between the GND and each injector 2. Measure the resistance between the GND and each injector
terminal. terminal.

Reference value No Reference value No


10 MΩ Go to step 19. 10 MΩ Go to step 19.
Is the resistance at or above the reference value? Is the resistance at or above the reference value?
Step 14 Step 14
1. Turn the key switch "OFF". Yes 1. Turn the key switch "OFF". Yes
2. Remove the injector side harness connector from the 2. Remove the injector side harness connector from the
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Connect the DMM between the GND and the No. 2 cylinder No Reference value 3. Connect the DMM between the GND and the No. 2 cylinder No Reference value
injector drive circuit. 0V injector drive circuit. 0V
CN.A3 female side No. 7 Is the DMM display the reference value? CN.A3 female side No. 7 Is the DMM display the reference value?
4. Turn the key switch "ON". 4. Turn the key switch "ON".
Yes Yes
Go to step 15. Go to step 15.

Go to step 13. Go to step 13.

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4021-182 4021-182

Step 13 Step 13
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the injector side harness connector from the 2. Remove the injector side harness connector from the
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Connect the DMM between the GND and the No. 3 cylinder 3. Connect the DMM between the GND and the No. 3 cylinder
injector drive circuit. injector drive circuit.
CN.A3 female side No. 6. CN.A3 female side No. 6.
4. Turn the key switch "ON". No Reference value 4. Turn the key switch "ON". No Reference value
0V 0V
Is the DMM display at or above the reference value? Is the DMM display at or above the reference value?

Step 14 Yes Step 14 Yes


1. Turn the key switch "OFF". Go to step 16. 1. Turn the key switch "OFF". Go to step 16.
2. Remove the injector side harness connector from the 2. Remove the injector side harness connector from the
intermediate connector (CN.A3). intermediate connector (CN.A3).
3. Connect the DMM between the GND and the injector power 3. Connect the DMM between the GND and the injector power
supply 2 circuit. supply 2 circuit.
CN.A3 female side No. 3 CN.A3 female side No. 3
4. Turn the key switch "ON". Reference value No 4. Turn the key switch "ON". Reference value No
7.0 V Go to step 17. 7.0 V Go to step 17.
Is the DMM display at or below the reference value? Is the DMM display at or below the reference value?

Yes Yes
Go to step 18. Go to step 18.

From step 12 From step 12


Step 15 Step 15
1. Use the breaker box or DMM to check whether a short 1. Use the breaker box or DMM to check whether a short
circuit with the power supply circuit or ignition power supply circuit with the power supply circuit or ignition power supply
circuit is present in the No. 2 cylinder injector drive circuit circuit is present in the No. 2 cylinder injector drive circuit
between the ECM and the intermediate connector (CN.A3). between the ECM and the intermediate connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20. If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20.
sensors on actual machine. sensors on actual machine.
2. Correct as necessary if a problem is detected. 2. Correct as necessary if a problem is detected.
Yes Yes
Go to step 23. Go to step 23.

From step 13 From step 13


Step 16 Step 16
1. Use the breaker box or DMM to check whether a short 1. Use the breaker box or DMM to check whether a short
circuit with the power supply circuit or ignition power supply circuit with the power supply circuit or ignition power supply
circuit is present in the No. 2 cylinder injector drive circuit circuit is present in the No. 2 cylinder injector drive circuit
between the ECM and the intermediate connector (CN.A3). between the ECM and the intermediate connector (CN.A3).
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20. If there is no breaker box, see the Inspection procedures for Was a problem detected? Go to step 20.
sensors on actual machine. sensors on actual machine.
2. Correct as necessary if a problem is detected. 2. Correct as necessary if a problem is detected.
Yes Yes
Go to step 23. Go to step 23.

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4021-183 4021-183

Step 21 From step 14 Step 21 From step 14


1. Use the breaker box or DMM to check whether a short 1. Use the breaker box or DMM to check whether a short
circuit with the power supply circuit or ignition power circuit with the power supply circuit or ignition power
supply circuit is present in the injector power supply 2 supply circuit is present in the injector power supply 2
circuit between the ECM and the intermediate circuit between the ECM and the intermediate
connector (CN.A3). No connector (CN.A3). No
See the Breaker Box Inspection Procedure. Was a problem detected? See the Breaker Box Inspection Procedure. Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. Yes for sensors on actual machine. Yes
Go to step 23. Go to step 23.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

From step 14 From step 14

Step 18 Step 18
Replace the injector harness. Replace the injector harness.

Is the action complete? Is the action complete?

Yes Yes
Go to step 23. Go to step 23.
Step 19 Step 19
Replace the injector. From step 11 Replace the injector. From step 11
Note: Note:
See the "Engine" section in the Service Manual for the See the "Engine" section in the Service Manual for the
work procedures. work procedures.

Is the action complete? Is the action complete?

Step 21 Step 21
1. Check the ECM software version. Yes 1. Check the ECM software version. Yes
Go to step 23. Go to step 23.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
"How to Use EMPS". "How to Use EMPS".
Note: No Step 20 Note: No Step 20
When ECM replacement or rewriting is performed, Is there an EMPS? When ECM replacement or rewriting is performed, Is there an EMPS?
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
3. Turn the key switch "ON". Yes 3. Turn the key switch "ON". Yes
4. Turn the key switch "OFF". 4. Turn the key switch "OFF".
5. Wait about 10 sec. 5. Wait about 10 sec.

No No
Is the action complete? Is the action complete?
Step 22 Step 22
Replace the ECM. Yes Replace the ECM. Yes
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.
Is the action complete? Is the action complete?

Step 23 Yes Step 23 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
3. Turn the key switch "OFF" for at least 10 sec. No Has a diagnostic trouble code: 1262 been 3. Turn the key switch "OFF" for at least 10 sec. No Has a diagnostic trouble code: 1262 been
4. Perform a test drive under the "Preconditions when detected? 4. Perform a test drive under the "Preconditions when detected?
diagnostic trouble code is set". diagnostic trouble code is set".
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes
Go to step 2. Go to step 2.

Step 24 Step 24
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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4021-184 4021-184
Block diagram Block diagram

CYLINDER #1 CYLINDER #1

CYLINDER #4 CYLINDER #4

CYLINDER #2 CYLINDER #2

CYLINDER #3 CYLINDER #3

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• Main relay power supply voltage is 18 V or higher. • Main relay power supply voltage is 18 V or higher.
• At least 70 min-1 • At least 70 min-1
• DTC: 0202, 0203, 0612, and 1262 are not detected. • DTC: 0202, 0203, 0612, and 1262 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-185 4021-185
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
• Remove the ECM-side • Remove the ECM-side
Resistance harness connector Resistance harness connector
Disconnection/ 116-Female-side termi- 100 Ω or 10 M Ω or Disconnection/ 116-Female-side termi- 100 Ω or 10 M Ω or
measure- from the intermediate measure- from the intermediate
high resistance nal (CN. A3 No. 2) lower higher high resistance nal (CN. A3 No. 2) lower higher
ment connector. ment connector.
• Key switch "OFF" • Key switch "OFF"
5 5
• Remove the ECM-side • Remove the ECM-side
Resistance harness connector Resistance harness connector
from the intermediate 10 M Ω 100 Ω or from the intermediate 10 M Ω 100 Ω or
Short circuit with GND measure- 116-GND Short circuit with GND measure- 116-GND
connector. or higher lower connector. or higher lower
ment ment
• Key switch "OFF" • Key switch "OFF"
• Remove the ECM-side • Remove the ECM-side
Resistance harness connector Resistance harness connector
10 M Ω 100 Ω or 10 M Ω 100 Ω or
8 Short circuit with GND measure- from the intermediate 115-GND 8 Short circuit with GND measure- from the intermediate 115-GND
or higher lower or higher lower
ment connector. ment connector.
• Key switch "OFF" • Key switch "OFF"
• Remove the ECM-side • Remove the ECM-side
Resistance harness connector Resistance harness connector
from the intermediate 10 M Ω 100 Ω or from the intermediate 10 M Ω 100 Ω or
9 Short circuit with GND measure- 120-GND 9 Short circuit with GND measure- 120-GND
connector. or higher lower connector. or higher lower
ment ment
• Key switch "OFF" • Key switch "OFF"
• Remove the ECM-side • Remove the ECM-side
Voltage harness connector Voltage harness connector
Short circuit with power 18 V or Short circuit with power 18 V or
15 value mea- from the intermediate 115-GND 0V 15 value mea- from the intermediate 115-GND 0V
supply circuit higher supply circuit higher
surement connector. surement connector.
• Key switch "OFF" • Key switch "OFF"
• Remove the ECM-side • Remove the ECM-side
Voltage harness connector Voltage harness connector
Short circuit with power from the intermediate 18 V or Short circuit with power from the intermediate 18 V or
16 value mea- 120-GND 0V 16 value mea- 120-GND 0V
supply circuit higher supply circuit higher
surement connector. surement connector.
• Key switch "OFF" • Key switch "OFF"
• Remove the ECM-side • Remove the ECM-side
Voltage harness connector Voltage harness connector
Short circuit with power 18 V or Short circuit with power 18 V or
17 value mea- from the intermediate 116-GND 0V 17 value mea- from the intermediate 116-GND 0V
supply circuit higher supply circuit higher
surement connector. surement connector.
• Key switch "OFF" • Key switch "OFF"

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4021-186 4021-186
DTC: 1345 DTC: 1345
CMP (cam position) Sensor Out of Phase CMP (cam position) Sensor Out of Phase

No change in behavior while the engine is turning, and restarting is not No change in behavior while the engine is turning, and restarting is not
possible after the engine is stopped. possible after the engine is stopped.

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to "Service support check". Is the action complete? Go to "Service support check".
Step 2 Step 2
1. Inspect the CMP sensor state. Yes 1. Inspect the CMP sensor state. Yes
• Harness connector connection problem • Harness connector connection problem
• Sensor installation looseness, backlash • Sensor installation looseness, backlash
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Is the action complete? Is the action complete?


Step 3 Step 3
1. Inspect the CKP (crank position) sensor state. 1. Inspect the CKP (crank position) sensor state.
• Harness connector connection problem Yes • Harness connector connection problem Yes
• Sensor installation looseness, backlash • Sensor installation looseness, backlash
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Is the action complete? Is the action complete?

Step 4 Yes Step 4 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Delete the diagnostic trouble code. 1. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
2. Turn the key switch "OFF" for at least 10 sec. 2. Turn the key switch "OFF" for at least 10 sec.
3. Perform a test drive under the "Preconditions when 3. Perform a test drive under the "Preconditions when
diagnostic trouble code is set". diagnostic trouble code is set".
4. Confirm the diagnostic trouble code. 4. Confirm the diagnostic trouble code.
• Stop the engine once, crank for 4 - 5 sec., and check • Stop the engine once, crank for 4 - 5 sec., and check
if diagnostic trouble code: 0340 is detected. if diagnostic trouble code: 0340 is detected.
• If diagnostic trouble code: 0340 is detected, judge to • If diagnostic trouble code: 0340 is detected, judge to
be a CMP sensor disconnection and inspect and be a CMP sensor disconnection and inspect and
repair the CMP sensor disconnection problem. repair the CMP sensor disconnection problem.
Crank for 10 sec. after repair and check that diagnos- Crank for 10 sec. after repair and check that diagnos-
tic trouble code: 0340, 1345 goes out. tic trouble code: 0340, 1345 goes out.

Has a diagnostic trouble code: 1345 been Has a diagnostic trouble code: 1345 been
detected? detected?
Step 5 Step 5
1. Inspect to see if the camshaft gear is correctly 1. Inspect to see if the camshaft gear is correctly
Yes Yes
installed. installed.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Is the action complete? Is the action complete?


Step 6 Step 6
1. Inspect to see if the flywheel is correctly installed. Yes 1. Inspect to see if the flywheel is correctly installed. Yes
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Is the action complete? Is the action complete?


Step 7 Step 7
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Delete the diagnostic trouble code. Yes 1. Delete the diagnostic trouble code. Yes
See the service support DIAG (trouble diagnosis) See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. codes.
2. Turn the key switch "OFF" for at least 10 sec. 2. Turn the key switch "OFF" for at least 10 sec.
3. Perform a test drive under the "Preconditions when 3. Perform a test drive under the "Preconditions when
diagnostic trouble code is set". diagnostic trouble code is set".
4. Confirm the diagnostic trouble code. No Has a diagnostic trouble code: 1345 been 4. Confirm the diagnostic trouble code. No Has a diagnostic trouble code: 1345 been
detected? detected?

Yes Yes

Step 8 Step 8
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

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4021-187 4021-187
Block diagram Block diagram

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Recovery from failure Recovery from failure


During trouble judgment, about 10 sec. of cranking is necessary. During trouble judgment, about 10 sec. of cranking is necessary.
Preconditions when DTC is set Preconditions when DTC is set
• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 0335, 0336, 0340, 0341, 1345 and 1635 are not detected. • DTC: 0335, 0336, 0340, 0341, 1345 and 1635 are not detected.
• CMP sensor signal is normal. • CMP sensor signal is normal.
• CKP sensor signal is normal. • CKP sensor signal is normal.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-188 4021-188
DTC: 1625 DTC: 1625
Main Relay System Abnormality Main Relay System Abnormality

The engine cannot be started or the power The engine cannot be started or the power
supply does not cut off. supply does not cut off.

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Go to "Service support No Go to "Service support


Is the action complete? Is the action complete?
check". check".

Yes Yes

Step 2 No Step 2 No
Go to step 17. Go to step 17.
Do you have a scan tool (KW communication)? Do you have a scan tool (KW communication)?

Step 3 Yes Step 3 Yes


1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Use the scan tool to check the "Main relay voltage" 2. Use the scan tool to check the "Main relay voltage"
display in the data display. display in the data display.

No Reference value No Reference value


1V 1V
Is the "Main relay voltage" value at or above the Is the "Main relay voltage" value at or above the
reference value? reference value?

Step 4 Yes Step 4 Yes


1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Confirm the diagnostic trouble code. 2. Confirm the diagnostic trouble code.

Step 5 Has a diagnostic trouble code: 1625 been Step 5 Has a diagnostic trouble code: 1625 been
Go to diagnostic aid. Go to diagnostic aid.
1. Remove the main relay. detected? 1. Remove the main relay. detected?
2. Confirm the diagnostic trouble code. 2. Confirm the diagnostic trouble code.
Note: Yes Note: Yes
For details on main relay installation position and For details on main relay installation position and
installation and removal, see the manual for the actual installation and removal, see the manual for the actual
machine. machine.
Has a diagnostic trouble code: 1625 been No Has a diagnostic trouble code: 1625 been No
Go to step 11. Go to step 11.
detected? detected?

Yes Yes
Step 6 Step 6
1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
short circuit with the power supply circuit or ignition short circuit with the power supply circuit or ignition
power supply circuit is present in the contact side power supply circuit is present in the contact side
circuit between the main relay and the ECM. circuit between the main relay and the ECM.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures Was a problem detected? Go to step 15. If there is no breaker box, see the Inspection procedures Was a problem detected? Go to step 15.
for sensors on actual machine. for sensors on actual machine.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
Yes Yes
Go to step 12. Go to step 12.

Step 7 Step 7
Check the installation status of the main relay, ECM Check the installation status of the main relay, ECM
connector, and intermediate connector. connector, and intermediate connector.
No No
1. Inspect whether there is any backlash or looseness in Was a problem detected? 1. Inspect whether there is any backlash or looseness in Was a problem detected?
the installation of the connectors. the installation of the connectors.
2. Correct as necessary if a problem is detected. 2. Correct as necessary if a problem is detected.
Yes Yes
Go to step 15. Go to step 15.

Step 8 Step 8
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the main relay. No Reference value 2. Remove the main relay. No Reference value
3. Use a jumper cable to create a short circuit between 24 V 3. Use a jumper cable to create a short circuit between 24 V
terminals 1 and 2 and terminals 3 and 5 of he main Is the "Main relay voltage" value at or above the terminals 1 and 2 and terminals 3 and 5 of he main Is the "Main relay voltage" value at or above the
relay installation section. reference value? relay installation section. reference value?
4. Turn the key switch "ON". Yes 4. Turn the key switch "ON". Yes
5. Use the scan tool to check the "Main relay voltage" Go to step 11. 5. Use the scan tool to check the "Main relay voltage" Go to step 11.
display in the data display. display in the data display.

Go to step 9. Go to step 9.

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4021-189 4021-189

Step 9 From step 8 Step 9 From step 8


1. Inspect whether the conditions below are present in the 1. Inspect whether the conditions below are present in the
circuit between the slow-blow fuse and the main relay. circuit between the slow-blow fuse and the main relay.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
• Disconnection • Disconnection
• Short circuit with GND circuit No • Short circuit with GND circuit No
• High resistance Was a problem detected? • High resistance Was a problem detected?
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Yes Yes
Go to step 15. Go to step 15.
Step 10 Step 10
1. Use the breaker box or DMM to inspect whether the 1. Use the breaker box or DMM to inspect whether the
conditions below are present in the circuit between the main conditions below are present in the circuit between the main
relay and ECM. relay and ECM.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures for If there is no breaker box, see the Inspection procedures for
sensors on actual machine. sensors on actual machine.
• Disconnection No • Disconnection No
• Short circuit with GND circuit Was a problem detected? • Short circuit with GND circuit Was a problem detected?
• High resistance • High resistance
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
Yes Yes

From steps 5, 8, 19, 22 From steps 5, 8, 19, 22

Step 11 Step 11
Replace the main relay. Replace the main relay.

Is the action complete? Is the action complete?

Step 13 Yes Step 13 Yes


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software version is 2. Perform rewriting if updating the ECM software version is
necessary. necessary.
For details on checking the ECM and the rewriting, see "How to For details on checking the ECM and the rewriting, see "How to
Use EMPS". No Use EMPS". No
Step 12 Step 12
Note: Note:
Is there an EMPS? Is there an EMPS?
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch "ON". 1. Turn the key switch "ON".
Yes Yes
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.

No No
Is the action complete? Is the action complete?

Yes Yes
Step 14 Step 14
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, perform When ECM replacement or rewriting is performed, perform
EGR learning. EGR learning.
[EGR learning method] [EGR learning method]
• Turn the key switch “ON”. • Turn the key switch “ON”.
• Turn the key switch “OFF”. • Turn the key switch “OFF”.
• Wait about 10 sec. Is the action complete? • Wait about 10 sec. Is the action complete?

Yes Yes

Step 15 Step 15
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. 2. Delete the diagnostic trouble code.
See the service support DIAG (trouble diagnosis) screen for No Has a diagnostic trouble code: 1625 been See the service support DIAG (trouble diagnosis) screen for No Has a diagnostic trouble code: 1625 been
information on deleting diagnostic trouble codes. detected? information on deleting diagnostic trouble codes. detected?
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when Yes 4. Perform a test drive under the “Preconditions when Yes
diagnostic trouble code is set”. Go to step 2. diagnostic trouble code is set”. Go to step 2.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 16 Step 16
Check that no other diagnostic trouble code has been detected. Check that no other diagnostic trouble code has been detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-190 4021-190

Step 17 From step 2 Step 17 From step 2


1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the main relay. 2. Remove the main relay.
3. Turn the key switch "ON". 3. Turn the key switch "ON".
4. Connect the DMM between the GND and the main 4. Connect the DMM between the GND and the main
relay connector coil side terminal. Reference value relay connector coil side terminal. Reference value
1V 1V
Is the DMM display at or above the reference value? Is the DMM display at or above the reference value?

Step 18 Yes Step 18 Yes


1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Confirm the diagnostic trouble code. 2. Confirm the diagnostic trouble code.

No No
Has a diagnostic trouble code: 1625 been detected? Go to diagnostic aid. Has a diagnostic trouble code: 1625 been detected? Go to diagnostic aid.
Step 19 Step 19
1. Confirm the diagnostic trouble code. 1. Confirm the diagnostic trouble code.
2. Remove the main relay. Yes 2. Remove the main relay. Yes
Note: Note:
For details on main relay installation position and For details on main relay installation position and
installation and removal, see the manual for the actual installation and removal, see the manual for the actual
machine. machine.

No No
Has a diagnostic trouble code: 1625 been detected? Go to step 11. Has a diagnostic trouble code: 1625 been detected? Go to step 11.

Step 20 Step 20
Yes Yes
1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
short circuit with the power supply circuit or ignition short circuit with the power supply circuit or ignition
power supply circuit is present in the contact side power supply circuit is present in the contact side
circuit between the main relay and the ECM. No circuit between the main relay and the ECM. No
See the Breaker Box Inspection Procedure. Was a problem detected? Go to step 15. See the Breaker Box Inspection Procedure. Was a problem detected? Go to step 15.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. Yes for sensors on actual machine. Yes
2. Repair as necessary if a problem is detected. Go to step 12. 2. Repair as necessary if a problem is detected. Go to step 12.

Step 21 Step 21
Check the installation status of the main relay, ECM Check the installation status of the main relay, ECM
connector, and intermediate connector. connector, and intermediate connector.
No No
1. Inspect whether there is any backlash or looseness in Was a problem detected? 1. Inspect whether there is any backlash or looseness in Was a problem detected?
the installation of the connectors. the installation of the connectors.
2. Correct as necessary if a problem is detected. 2. Correct as necessary if a problem is detected.
Yes Yes
Go to step 15. Go to step 15.

Step 22 Step 22
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the main relay. 2. Remove the main relay.
3. Turn the key switch "ON". Reference value No 3. Turn the key switch "ON". Reference value No
4. Connect the DMM between the GND and the main 24 V Go to step 9. 4. Connect the DMM between the GND and the main 24 V Go to step 9.
relay connector coil side terminal. Is the DMM display at or above the reference value? relay connector coil side terminal. Is the DMM display at or above the reference value?

Yes Yes
Go to step 11. Go to step 11.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-191 4021-191
Block diagram Block diagram

RELAY R1 MAIN RELAY R1 MAIN

FUSE F4 FUSE F4

BATTERY BATTERY
(24V) (24V)

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input voltage is 18 V or higher. • Key switch input voltage is 18 V or higher.
• DTC: 1630 is not detected. • DTC: 1630 is not detected.
• 3 sec. or more passed after key switched ON. • 3 sec. or more passed after key switched ON.
• Main relay drive command ON • Main relay drive command ON
• DTC: 0606, 1625 are not detected. • DTC: 0606, 1625 are not detected.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

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4021-192 4021-192
Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage Voltage
Short circuit with power • Remove the relay. 2-GND 18 V or Short circuit with power • Remove the relay. 2-GND 18 V or
6 value mea- 0V 6 value mea- 0V
supply circuit • Key switch "ON" 5-GND higher supply circuit • Key switch "ON" 5-GND higher
surement surement
2-Relay installation 2-Relay installation
section No. 2 terminal section No. 2 terminal
5-Relay installation 5-Relay installation
Resistance Resistance
Disconnection/ • Remove the relay. section No. 2 terminal 100 Ω or 10 M Ω or Disconnection/ • Remove the relay. section No. 2 terminal 100 Ω or 10 M Ω or
measure- measure-
high resistance • Key switch "OFF" 21-Relay installation lower higher high resistance • Key switch "OFF" 21-Relay installation lower higher
ment ment
section No. 5 terminal section No. 5 terminal
10 40-Relay installation 10 40-Relay installation
section No. 5 terminal section No. 5 terminal
2-GND 2-GND
Resistance Resistance
• Remove the relay. 5-GND 10 M Ω 100 Ω or • Remove the relay. 5-GND 10 M Ω 100 Ω or
Short circuit with GND measure- Short circuit with GND measure-
• Key switch "OFF" 21-GND or higher lower • Key switch "OFF" 21-GND or higher lower
ment ment
40-GND 40-GND

Inspection procedures for sensors on actual machine Inspection procedures for sensors on actual machine
1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector. 1. Disconnect the intermediate connectors and perform sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short circuit the sensor connector wiring. 2. Disconnect the connector from the sensor and short circuit the sensor connector wiring.
3. Inspect the harness disconnection from the intermediate connector. 3. Inspect the harness disconnection from the intermediate connector.
• If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1. • If there is an abnormality in both procedures 1 and 2, repair the harness and repeat inspection from procedure 1.
• If there is an abnormality in procedure 1 only, replace the sensor. • If there is an abnormality in procedure 1 only, replace the sensor.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-193 4021-193
DTC: 1630 DTC: 1630
A/D Conversion Abnormality A/D Conversion Abnormality

Drop of output power, black smoke Drop of output power, black smoke

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No Go to "Service support No Go to "Service support


Is the action complete? Is the action complete?
Step 2 check". Step 2 check".
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Delete the diagnostic trouble code. Yes 1. Delete the diagnostic trouble code. Yes
2. See the service support DIAG (trouble diagnosis) 2. See the service support DIAG (trouble diagnosis)
screen for information on deleting diagnostic trouble screen for information on deleting diagnostic trouble
codes. No codes. No
3. Turn the key switch "OFF" for at least 10 sec. Has a diagnostic trouble code: 1630 been 3. Turn the key switch "OFF" for at least 10 sec. Has a diagnostic trouble code: 1630 been
Go to diagnostic aid. Go to diagnostic aid.
4. Perform a test drive under the "Preconditions when detected? 4. Perform a test drive under the "Preconditions when detected?
diagnostic trouble code is set". diagnostic trouble code is set".
5. Confirm the diagnostic trouble code. Yes 5. Confirm the diagnostic trouble code. Yes

Step 4 No Step 3 Step 4 No Step 3


1. Check the ECM software version. Is there an EMPS? 1. Check the ECM software version. Is there an EMPS?
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. Yes version is necessary. Yes
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
"How to Use EMPS". "How to Use EMPS".
Note: Note:
When ECM replacement or rewriting is performed, No When ECM replacement or rewriting is performed, No
perform EGR learning. Is the action complete? perform EGR learning. Is the action complete?
[EGR learning method] [EGR learning method]
1. Turn the key switch "ON". 1. Turn the key switch "ON".
Yes Yes
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 5 Step 5
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, Is the action complete? When ECM replacement or rewriting is performed, Is the action complete?
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch "ON". Yes 1. Turn the key switch "ON". Yes
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 6 Step 6
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-194 4021-194
DTC: 1632 DTC: 1632
5 V Power Supply 2 Voltage Abnormality (atmospheric pressure sensor power supply) 5 V Power Supply 2 Voltage Abnormality (atmospheric pressure sensor power supply)

Backup is equivalent to 2500 m, so at heights, black Backup is equivalent to 2500 m, so at heights, black
smoke is generated and in low areas, power is smoke is generated and in low areas, power is
inadequate. inadequate.

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to "Service support check". Is the action complete? Go to "Service support check".

Step 2 Yes Step 2 Yes


1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove atmospheric pressure sensor connector. 2. Remove atmospheric pressure sensor connector.
3. Connect the DMM between the GND and the 3. Connect the DMM between the GND and the
power supply terminal of the atmospheric pressure power supply terminal of the atmospheric pressure
sensor. sensor.
4. Turn the key switch "ON". No Reference value 4. Turn the key switch "ON". No Reference value
5.5 V 5.5 V
Is the DMM display at or above the reference value? Is the DMM display at or above the reference value?

Yes Yes

Step 3 Step 3
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the atmospheric pressure sensor 2. Remove the atmospheric pressure sensor
connector. connector.
3. Connect the DMM between the GND and the 3. Connect the DMM between the GND and the
power supply terminal of the atmospheric pressure No power supply terminal of the atmospheric pressure No
sensor. Reference value Go to diagnostic aid. sensor. Reference value Go to diagnostic aid.
4. Turn the key switch "ON". 4.5 V 4. Turn the key switch "ON". 4.5 V
Is the DMM display at or below the reference value? Is the DMM display at or below the reference value?

Step 4 Yes Step 4 Yes


1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
short circuit with the battery power supply circuit or short circuit with the battery power supply circuit or
ignition power supply circuit is present in the ignition power supply circuit is present in the
power supply circuit between the ECM and power supply circuit between the ECM and
atmospheric pressure sensor. atmospheric pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection Was a problem detected? If there is no breaker box, see the Inspection Was a problem detected?
procedures for sensors on actual machine. procedures for sensors on actual machine.
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 9. Go to step 9.

Step 5 Step 5
1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
short circuit with GND is present in the power short circuit with GND is present in the power
supply circuit between the ECM and atmospheric No supply circuit between the ECM and atmospheric No
pressure sensor. Was a problem detected? pressure sensor. Was a problem detected?
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Yes Note: Yes
If there is no breaker box, see the Inspection Go to step 9. If there is no breaker box, see the Inspection Go to step 9.
procedures for sensors on actual machine. procedures for sensors on actual machine.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 6 No Step 6 No
Go to step 8. Go to step 8.
Is there an EMPS? Is there an EMPS?

Yes Yes

Go to step 7. Go to step 7.

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4021-195 4021-195

Step 7 From step 6 Step 7 From step 6


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
"How to Use EMPS". No "How to Use EMPS". No
Note: Is the action complete? Note: Is the action complete?
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
EGR learning method Yes EGR learning method Yes
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 8 Step 8
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning Is the action complete? perform EGR learning Is the action complete?
EGR learning method EGR learning method
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". Yes 2. Turn the key switch "OFF". Yes
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 9 Step 9
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. No 2. Delete the diagnostic trouble code. No
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 1632 been See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 1632 been
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
3. Turn the key switch "OFF" for at least 10 sec. Yes 3. Turn the key switch "OFF" for at least 10 sec. Yes
4. Perform a test drive under the "Preconditions when Go to step 2. 4. Perform a test drive under the "Preconditions when Go to step 2.
diagnostic trouble code is set". diagnostic trouble code is set".
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 10 Step 10
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-196 4021-196
Block diagram Block diagram

BARO SENSOR BARO SENSOR

AIR INTAKE TEMP. SENSOR AIR INTAKE TEMP. SENSOR

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• DTC: 1630 is not detected. • DTC: 1630 is not detected.
• Key switch input power supply voltage is higher than 16 V and lower than 32 V. • Key switch input power supply voltage is higher than 16 V and lower than 32 V.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-197 4021-197
DTC: 1633 DTC: 1633
5 V Power Supply 3 Voltage Abnormality (engine oil pressure power supply) 5 V Power Supply 3 Voltage Abnormality (engine oil pressure power supply)

There is a possibility of deterioration of starting at There is a possibility of deterioration of starting at


low temperatures and black smoke and an effect on low temperatures and black smoke and an effect on
machine operability machine operability

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to "Service support check". Is the action complete? Go to "Service support check".

Step 2 Yes Step 2 Yes


1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the engine oil pressure sensor connector. 2. Remove the engine oil pressure sensor connector.
3. Connect the DMM between the GND and the 3. Connect the DMM between the GND and the
power supply terminal of the engine oil pressure power supply terminal of the engine oil pressure
sensor. sensor.
4. Turn the key switch "ON". No Reference value 4. Turn the key switch "ON". No Reference value
5.5 V 5.5 V
Is the DMM display at or above the reference value? Is the DMM display at or above the reference value?

Yes Yes

Step 3 Step 3
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the engine oil pressure sensor 2. Remove the engine oil pressure sensor
connector. connector.
3. Connect the DMM between the GND and the 3. Connect the DMM between the GND and the
power supply terminal of the engine oil pressure power supply terminal of the engine oil pressure
sensor. sensor.
4. Turn the key switch "ON". Reference value No 4. Turn the key switch "ON". Reference value No
4.5 V Go to diagnostic aid. 4.5 V Go to diagnostic aid.
Is the DMM display at or below the reference value? Is the DMM display at or below the reference value?

Step 4 Yes Step 4 Yes


1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
short circuit with the battery power supply circuit or short circuit with the battery power supply circuit or
ignition power supply circuit is present in the ignition power supply circuit is present in the
power supply circuit between the ECM and engine power supply circuit between the ECM and engine
oil pressure sensor. oil pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection Was a problem detected? If there is no breaker box, see the Inspection Was a problem detected?
procedures for sensors on actual machine. procedures for sensors on actual machine.
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 9. Go to step 9.

Step 5 Step 5
1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
short circuit with GND is present in the power short circuit with GND is present in the power
supply circuit between the ECM and engine oil No supply circuit between the ECM and engine oil No
pressure sensor. Was a problem detected? pressure sensor. Was a problem detected?
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Yes Note: Yes
If there is no breaker box, see the Inspection Go to step 9. If there is no breaker box, see the Inspection Go to step 9.
procedures for sensors on actual machine. procedures for sensors on actual machine.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 6 No Step 6 No
Go to step 8. Go to step 8.
Is there an EMPS? Is there an EMPS?

Yes Yes

Go to step 7. Go to step 7.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-198 4021-198

Step 7 From step 6 Step 7 From step 6


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
"How to Use EMPS". No "How to Use EMPS". No
Note: Is the action complete? Note: Is the action complete?
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
EGR learning method Yes EGR learning method Yes
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 8 Step 8
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning Is the action complete? perform EGR learning Is the action complete?
EGR learning method EGR learning method
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". Yes 2. Turn the key switch "OFF". Yes
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 9 Step 9
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. No 2. Delete the diagnostic trouble code. No
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 1633 been See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 1633 been
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
3. Turn the key switch "OFF" for at least 10 sec. Yes 3. Turn the key switch "OFF" for at least 10 sec. Yes
4. Perform a test drive under the "Preconditions when Go to step 2. 4. Perform a test drive under the "Preconditions when Go to step 2.
diagnostic trouble code is set". diagnostic trouble code is set".
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 10 Step 10
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-199 4021-199
Block diagram Block diagram

OIL PRESS. SENSOR OIL PRESS. SENSOR

WATER TEMP. SENSOR WATER TEMP. SENSOR

FUEL TEMP. SENSOR FUEL TEMP. SENSOR

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• DTC: 1630 is not detected. • DTC: 1630 is not detected.
• Key switch input power supply voltage is higher than 16 V and lower than 32 V. • Key switch input power supply voltage is higher than 16 V and lower than 32 V.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-200 4021-200
DTC: 1634 DTC: 1634
5 V Power Supply 4 Voltage Abnormality (boost pressure sensor power supply) 5 V Power Supply 4 Voltage Abnormality (boost pressure sensor power supply)

Possible impact on machine operability Possible impact on machine operability

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to "Service support check". Is the action complete? Go to "Service support check".

Step 2 Yes Step 2 Yes


1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the boost pressure sensor connector. 2. Remove the boost pressure sensor connector.
3. Connect the DMM between the GND and the 3. Connect the DMM between the GND and the
power supply terminal of the boost pressure power supply terminal of the boost pressure
sensor. sensor.
4. Turn the key switch "ON". No Reference value 4. Turn the key switch "ON". No Reference value
5.5 V 5.5 V
Is the DMM display at or above the reference value? Is the DMM display at or above the reference value?

Yes Yes

Step 3 Step 3
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the boost pressure sensor connector. 2. Remove the boost pressure sensor connector.
3. Connect the DMM between the GND and the 3. Connect the DMM between the GND and the
power supply terminal of the boost pressure power supply terminal of the boost pressure
sensor. sensor.
4. Turn the key switch "ON". No 4. Turn the key switch "ON". No
Reference value Go to diagnostic aid. Reference value Go to diagnostic aid.
4.5 V 4.5 V
Is the DMM display at or below the reference value? Is the DMM display at or below the reference value?

Step 4 Yes Step 4 Yes


1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
short circuit with the battery power supply circuit or short circuit with the battery power supply circuit or
ignition power supply circuit is present in the ignition power supply circuit is present in the
power supply circuit between the ECM and boost power supply circuit between the ECM and boost
pressure sensor. pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection Was a problem detected? If there is no breaker box, see the Inspection Was a problem detected?
procedures for sensors on actual machine. procedures for sensors on actual machine.
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 9. Go to step 9.

Step 5 Step 5
1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
short circuit with GND is present in the power short circuit with GND is present in the power
supply circuit between the ECM and boost No supply circuit between the ECM and boost No
pressure sensor. Was a problem detected? pressure sensor. Was a problem detected?
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Yes Note: Yes
If there is no breaker box, see the Inspection Go to step 9. If there is no breaker box, see the Inspection Go to step 9.
procedures for sensors on actual machine. procedures for sensors on actual machine.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

No No
Is there an EMPS? Go to step 8. Is there an EMPS? Go to step 8.

Yes Yes

Go to step 7. Go to step 7.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-201 4021-201

Step 7 From step 6 Step 7 From step 6


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
"How to Use EMPS". No "How to Use EMPS". No
Note: Is the action complete? Note: Is the action complete?
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
EGR learning method Yes EGR learning method Yes
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 8 Step 8
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning Is the action complete? perform EGR learning Is the action complete?
EGR learning method EGR learning method
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". Yes 2. Turn the key switch "OFF". Yes
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 9 Step 9
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. No 2. Delete the diagnostic trouble code. No
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 1634 been See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 1634 been
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
3. Turn the key switch "OFF" for at least 10 sec. Yes 3. Turn the key switch "OFF" for at least 10 sec. Yes
4. Perform a test drive under the "Preconditions when Go to step 2. 4. Perform a test drive under the "Preconditions when Go to step 2.
diagnostic trouble code is set". diagnostic trouble code is set".
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 10 Step 10
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-202 4021-202
Block diagram Block diagram

BOOST PRESS. SENSOR BOOST PRESS. SENSOR

BOOST TEMP. SENSOR BOOST TEMP. SENSOR

659) 659)

Preconditions when DTC is set Preconditions when DTC is set


• DTC: 1630 is not detected. • DTC: 1630 is not detected.
• Key switch input power supply voltage is higher than 16 V and lower than 32 V. • Key switch input power supply voltage is higher than 16 V and lower than 32 V.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-203 4021-203
DTC: 1635 DTC: 1635
5 V Power Supply 5 Voltage Abnormality 5 V Power Supply 5 Voltage Abnormality
(common rail pressure sensor, EGR position sensor power supply) (common rail pressure sensor, EGR position sensor power supply)

Engine rev-up, drop of output power, black smoke, Engine rev-up, drop of output power, black smoke,
and engine stalling are possible. and engine stalling are possible.

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to "Service support check". Is the action complete? Go to "Service support check".

Step 2 Yes Step 2 Yes


1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the common rail pressure sensor 2. Remove the common rail pressure sensor
connector. connector.
3. Connect the DMM between the GND and the 3. Connect the DMM between the GND and the
power supply terminal of the common rail pressure power supply terminal of the common rail pressure
sensor. Reference value sensor. Reference value
4. Turn the key switch "ON". No 5.5 V 4. Turn the key switch "ON". No 5.5 V
Is the DMM display at or above the reference value? Is the DMM display at or above the reference value?

Yes Yes

Step 3 Step 3
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the common rail pressure sensor 2. Remove the common rail pressure sensor
connector. connector.
3. Connect the DMM between the GND and the 3. Connect the DMM between the GND and the
power supply terminal of the common rail pressure No power supply terminal of the common rail pressure No
sensor. Reference value Go to diagnostic aid. sensor. Reference value Go to diagnostic aid.
4. Turn the key switch "ON". 4.5 V 4. Turn the key switch "ON". 4.5 V
Is the DMM display at or below the reference value? Is the DMM display at or below the reference value?

Step 4 Yes Step 4 Yes


1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
short circuit with the battery power supply circuit or short circuit with the battery power supply circuit or
ignition power supply circuit is present in the ignition power supply circuit is present in the
power supply circuit between the ECM and power supply circuit between the ECM and
common rail pressure sensor. common rail pressure sensor.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection Was a problem detected? If there is no breaker box, see the Inspection Was a problem detected?
procedures for sensors on actual machine. procedures for sensors on actual machine.
2. Repair as necessary if a problem is detected. Yes 2. Repair as necessary if a problem is detected. Yes
Go to step 9. Go to step 9.

Step 5 Step 5
1. Use the breaker box or DMM to inspect whether a 1. Use the breaker box or DMM to inspect whether a
short circuit with GND is present in the power short circuit with GND is present in the power
supply circuit between the ECM and common rail No supply circuit between the ECM and common rail No
pressure sensor. Was a problem detected? pressure sensor. Was a problem detected?
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Yes Note: Yes
If there is no breaker box, see the Inspection Go to step 9. If there is no breaker box, see the Inspection Go to step 9.
procedures for sensors on actual machine. procedures for sensors on actual machine.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 6 No Step 6 No
Go to step 8. Go to step 8.
Is there an EMPS? Is there an EMPS?

Yes Yes

Go to step 7. Go to step 7.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-204 4021-204

Step 7 From step 6 Step 7 From step 6


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
"How to Use EMPS". No "How to Use EMPS". No
Note: Is the action complete? Note: Is the action complete?
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
EGR learning method Yes EGR learning method Yes
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 8 Step 8
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning Is the action complete? perform EGR learning Is the action complete?
EGR learning method EGR learning method
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". Yes 2. Turn the key switch "OFF". Yes
3. Wait about 10 sec. 3. Wait about 10 sec.

Step 9 Step 9
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. No 2. Delete the diagnostic trouble code. No
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 1635 been See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 1635 been
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
3. Turn the key switch "OFF" for at least 10 sec. Yes 3. Turn the key switch "OFF" for at least 10 sec. Yes
4. Perform a test drive under the "Preconditions when Go to step 2. 4. Perform a test drive under the "Preconditions when Go to step 2.
diagnostic trouble code is set". diagnostic trouble code is set".
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 10 Step 10
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-205 4021-205
Block diagram Block diagram

EGR MOTOR EGR MOTOR

EGR POSITION SENSOR EGR POSITION SENSOR

COMMON RAIL PRESS. SENSOR COMMON RAIL PRESS. SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

65*- 65*-

Preconditions when DTC is set Preconditions when DTC is set


• DTC: 1630 is not detected. • DTC: 1630 is not detected.
• Key switch input power supply voltage is higher than 16 V and lower than 32 V. • Key switch input power supply voltage is higher than 16 V and lower than 32 V.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-206 4021-206
DTC: 2104 DTC: 2104
CAN Bus Abnormality CAN Bus Abnormality

Depends on the setting Depends on the setting

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to "Service support check". Is the action complete? Go to "Service support check".
Step 2 Step 2
1. Turn the key switch "OFF" for at least 10 sec. 1. Turn the key switch "OFF" for at least 10 sec.
Yes Yes
2. Start the engine. 2. Start the engine.
3. Confirm the diagnostic trouble code. 3. Confirm the diagnostic trouble code.

Has a diagnostic trouble code: 2104 been No Has a diagnostic trouble code: 2104 been No
Go to diagnostic aid. Go to diagnostic aid.
detected? detected?
Step 3 Step 3
4. With a diagnostic trouble code: 2104 detected, if the Yes 4. With a diagnostic trouble code: 2104 detected, if the Yes
past breakdowns for diagnostic trouble code: 2104 past breakdowns for diagnostic trouble code: 2104
and the current breakdown are detected alternately, and the current breakdown are detected alternately,
inspect whether the conditions below are present in inspect whether the conditions below are present in
the circuit between ECM terminal (32) and ECM the circuit between ECM terminal (32) and ECM
terminal (18). No terminal (18). No
• Short Is the action complete? • Short Is the action complete?
5. Repair or replace as necessary if a problem is 5. Repair or replace as necessary if a problem is
detected. detected.
6. Check that no diagnostic trouble codes have been 6. Check that no diagnostic trouble codes have been
redetected. redetected.

Step 4 No Step 4 No
Go to step 15. Go to step 15.
Step 5 Do you have a breaker box? Step 5 Do you have a breaker box?
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the ECM. Yes 2. Remove the ECM. Yes
3. Connect the breaker box to the ECM. 3. Connect the breaker box to the ECM.
4. Connect the ECM harness and the breaker box. 4. Connect the ECM harness and the breaker box.
5. Use the breaker box to measure the resistance 5. Use the breaker box to measure the resistance
between the CAN-High side terminal and the CAN- between the CAN-High side terminal and the CAN-
Low side terminal. Low side terminal.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.

No Reference value No Reference value


50 - 70 Ω 50 - 70 Ω
Is the resistance within the reference value Is the resistance within the reference value
range? range?
Step 6 Step 6
Yes Yes
Remove the ECM from the breaker box.Use the breaker Go to step 13. Remove the ECM from the breaker box.Use the breaker Go to step 13.
box to measure the resistance between the CAN-High box to measure the resistance between the CAN-High
side terminal and the CAN-Low side terminal. side terminal and the CAN-Low side terminal.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. for sensors on actual machine.

Reference value No Reference value No


About 120 Ω Go to step 8. About 120 Ω Go to step 8.
Is the resistance at the reference value? Is the resistance at the reference value?
Step 7 Step 7
1. Connect the ECM to the breaker box. Yes 1. Connect the ECM to the breaker box. Yes
2. Remove computer A and the harness. 2. Remove computer A and the harness.
3. Use the breaker box to measure the resistance 3. Use the breaker box to measure the resistance
between the CAN-High side terminal and the CAN- between the CAN-High side terminal and the CAN-
Low side terminal. Low side terminal.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Note:
If there is no breaker box, see the Inspection procedures Reference value No If there is no breaker box, see the Inspection procedures Reference value No
for sensors on actual machine. About 120 Ω Go to step 10. for sensors on actual machine. About 120 Ω Go to step 10.
Is the resistance at the reference value? Is the resistance at the reference value?

Yes Yes

Go to step 13. Go to step 13.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-207 4021-207

From step 6 From step 6


Step 8 Step 8
1. Use the breaker box or DMM to check whether a short 1. Use the breaker box or DMM to check whether a short
circuit with the power supply circuit or ignition power circuit with the power supply circuit or ignition power
supply circuit is present in the CAN-Low circuit and supply circuit is present in the CAN-Low circuit and
CAN-High circuit between the ECM and computer A. CAN-High circuit between the ECM and computer A.
No No
See the Breaker Box Inspection Procedure. Was a problem detected? See the Breaker Box Inspection Procedure. Was a problem detected?
Note: Note:
If there is no breaker box, see the Inspection procedures If there is no breaker box, see the Inspection procedures
for sensors on actual machine. Yes for sensors on actual machine. Yes
2. Repair as necessary if a problem is detected. Go to step 2. 2. Repair as necessary if a problem is detected. Go to step 2.

Step 9 Step 9
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the CAN-Low circuit No conditions below are present in the CAN-Low circuit No
and CAN-High circuit between the ECM and computer Was a problem detected? Replace computer A. and CAN-High circuit between the ECM and computer Was a problem detected? Replace computer A.
A. A.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: Yes Note: Yes
If there is no breaker box, see the Inspection procedures Go to step 2. If there is no breaker box, see the Inspection procedures Go to step 2.
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance From step 7 • High resistance From step 7
• Short circuit with GND • Short circuit with GND
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
No Step 10 No Step 10
Is there an EMPS? Is there an EMPS?

Step 11 Yes Step 11 Yes


1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software 2. Perform rewriting if updating the ECM software
version is necessary. version is necessary.
For details on checking the ECM and the rewriting, see For details on checking the ECM and the rewriting, see
"How to Use EMPS". "How to Use EMPS".
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch "ON". 1. Turn the key switch "ON".
No No
2. Turn the key switch "OFF". Is the action complete? 2. Turn the key switch "OFF". Is the action complete?
3. Wait about 10 sec. 3. Wait about 10 sec.

Yes Yes
Check repair. Check repair.
Step 12 Step 12
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch "ON". Is the action complete? 1. Turn the key switch "ON". Is the action complete?
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.
Yes Yes

Step 13 Step 13
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. No 2. Delete the diagnostic trouble code. No
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 2104 been See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 2104 been
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
3. Turn the key switch "OFF" for at least 10 sec. Yes 3. Turn the key switch "OFF" for at least 10 sec. Yes
4. Perform a test drive under the "Preconditions when Go to step 2. 4. Perform a test drive under the "Preconditions when Go to step 2.
diagnostic trouble code is set". diagnostic trouble code is set".
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 14 Step 14
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-208 4021-208

From step 4 From step 4

Step 15 Step 15
Remove the ECM and measure the resistance between Remove the ECM and measure the resistance between
the CAN-High side terminal and the CAN-Low side the CAN-High side terminal and the CAN-Low side
terminal of the ECM connector. Reference value No terminal of the ECM connector. Reference value No
About 120 Ω Go to step 8. About 120 Ω Go to step 8.
Is the resistance at the reference value? Is the resistance at the reference value?

Step 16 Yes Step 16 Yes


1. Install the ECM and remove computer A. 1. Install the ECM and remove computer A.
2. Measure the resistance between the CAN-High side 2. Measure the resistance between the CAN-High side
terminal and the CAN-Low side terminal of the terminal and the CAN-Low side terminal of the
computer A connector. Reference value No computer A connector. Reference value No
About 120 Ω Go to step 10. About 120 Ω Go to step 10.
Is the resistance at the reference value? Is the resistance at the reference value?

Yes Yes

Go to step 13. Go to step 13.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-209 4021-209
Block diagram Block diagram
CONTROLLER A CONTROLLER A

“CAN COMMUNICATION” “CAN COMMUNICATION”

Preconditions when DTC is set Preconditions when DTC is set


• Key switch input power supply voltage is 20 V or higher. • Key switch input power supply voltage is 20 V or higher.

Breaker box inspection procedure Breaker box inspection procedure


For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
Voltage • Remove all related Voltage • Remove all related
Short circuit with power 18-GND 18 V or Short circuit with power 18-GND 18 V or
8 value mea- ECU connectors. 0V 8 value mea- ECU connectors. 0V
supply circuit 37-GND higher supply circuit 37-GND higher
surement • Key switch "ON" surement • Key switch "ON"
Resistance • Remove all related Resistance • Remove all related
Disconnection/ 37-Computer A 100 Ω or 10 M Ω or Disconnection/ 37-Computer A 100 Ω or 10 M Ω or
measure- ECU connectors. measure- ECU connectors.
high resistance 18-Computer A lower higher high resistance 18-Computer A lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
9 9
Resistance • Remove all related Resistance • Remove all related
18-GND 10 M Ω 100 Ω or 18-GND 10 M Ω 100 Ω or
Short circuit with GND measure- ECU connectors. Short circuit with GND measure- ECU connectors.
37-GND or higher lower 37-GND or higher lower
ment • Key switch "OFF" ment • Key switch "OFF"

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-210 4021-210
DTC: 2106 DTC: 2106
CAN Time-out Abnormality CAN Time-out Abnormality

Depends on the setting. Depends on the setting.


Control from actual machine side stops working because CAN Control from actual machine side stops working because CAN
communication become impossible. The engine speed communication become impossible. The engine speed
becomes the actual machine backup speed. (1500 min-1) becomes the actual machine backup speed. (1500 min-1)

Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.

No No
Is the action complete? Go to Service support check. Is the action complete? Go to Service support check.
Step 2 Step 2
1. Turn the key switch “OFF” for at least 10 sec. 1. Turn the key switch “OFF” for at least 10 sec.
Yes Yes
2. Start the engine. 2. Start the engine.
3. Confirm the diagnostic trouble code. 3. Confirm the diagnostic trouble code.

Has a diagnostic trouble code: 2106 been No Has a diagnostic trouble code: 2106 been No
Go to diagnostic aid. Go to diagnostic aid.
detected? detected?
Step 3 Step 3
1. Use the breaker box or DMM to check whether the Yes 1. Use the breaker box or DMM to check whether the Yes
conditions below are present in the CAN- conditions below are present in the CAN-
Low circuit and CAN-High circuit between the ECM Low circuit and CAN-High circuit between the ECM
and computer A. and computer A.
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Note: No Note: No
If there is no breaker box, see the Inspection procedures Was a problem detected? If there is no breaker box, see the Inspection procedures Was a problem detected?
for sensors on actual machine. for sensors on actual machine.
• Disconnection • Disconnection
• High resistance Yes • High resistance Yes
2. Repair as necessary if a problem is detected. Go to step 11. 2. Repair as necessary if a problem is detected. Go to step 11.

Step 4 Step 4
1. Use the breaker box or DMM to check whether the 1. Use the breaker box or DMM to check whether the
conditions below are present in the CAN- conditions below are present in the CAN-
Low circuit and CAN-High circuit between the ECM No Low circuit and CAN-High circuit between the ECM No
and computer A. Was a problem detected? and computer A. Was a problem detected?
See the Breaker Box Inspection Procedure. See the Breaker Box Inspection Procedure.
Notes: Notes:
If there is no breaker box, see the Inspection procedures Yes If there is no breaker box, see the Inspection procedures Yes
for sensors on actual machine. Go to step 11. for sensors on actual machine. Go to step 11.
• Short circuit with GND circuit • Short circuit with GND circuit
• Short circuit with power supply circuit or ignition • Short circuit with power supply circuit or ignition
power supply circuit power supply circuit
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.

Step 5 Step 5
Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. No 2. Delete the diagnostic trouble code. No
See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 2106 been See the service support DIAG (trouble diagnosis) Has a diagnostic trouble code: 2106 been
Go to diagnostic aid. Go to diagnostic aid.
screen for information on deleting diagnostic trouble detected? screen for information on deleting diagnostic trouble detected?
codes. codes.
3. Turn the key switch “OFF” for at least 10 sec. 3. Turn the key switch “OFF” for at least 10 sec.
4. Perform a test drive under the “Preconditions when 4. Perform a test drive under the “Preconditions when
diagnostic trouble code is set”. diagnostic trouble code is set”.
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

Step 6 Step 6
With a diagnostic trouble code: 2104 detected, if the With a diagnostic trouble code: 2104 detected, if the
1. past breakdowns for diagnostic trouble code: 2106 1. past breakdowns for diagnostic trouble code: 2106
and the current breakdown are detected alternately, and the current breakdown are detected alternately,
inspect whether the conditions below are present in No Yes inspect whether the conditions below are present in No Yes
Is the action complete? Go to step 8. Is the action complete? Go to step 8.
the circuit between ECM terminal (32) and ECM the circuit between ECM terminal (32) and ECM
terminal (18). terminal (18).
• Short • Short
2. Repair or replace as necessary if a problem is 2. Repair or replace as necessary if a problem is
detected. detected.
3. Check that no diagnostic trouble codes have been 3. Check that no diagnostic trouble codes have been
redetected. Go to step 7. redetected. Go to step 7.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-211 4021-211

From step 6 From step 6

Step 7 Step 7
Replace computer A. Replace computer A.

Is the action complete? Is the action complete?

Yes Yes

From step 6 From step 6

Step 9 Step 9
1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM software No 2. Perform rewriting if updating the ECM software No
version is necessary. Step 8 version is necessary. Step 8
For details on checking the ECM and the rewriting, see Is there an EMPS? For details on checking the ECM and the rewriting, see Is there an EMPS?
"How to Use EMPS". "How to Use EMPS".
Note: Yes Note: Yes
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.
No No
Is the action complete? Is the action complete?

Yes Yes
Step 10 Step 10
Replace the ECM. Replace the ECM.
Note: Note:
When ECM replacement or rewriting is performed, When ECM replacement or rewriting is performed,
perform EGR learning. perform EGR learning.
[EGR learning method] [EGR learning method]
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch "OFF". 2. Turn the key switch "OFF".
3. Wait about 10 sec. 3. Wait about 10 sec.

Is the action complete? Is the action complete?

Step 11 Yes Step 11 Yes


Recheck the diagnostic trouble code. Recheck the diagnostic trouble code.
1. Connect all harnesses. 1. Connect all harnesses.
2. Delete the diagnostic trouble code. See the service 2. Delete the diagnostic trouble code. See the service
support DIAG (trouble diagnosis) screen for support DIAG (trouble diagnosis) screen for
information on deleting diagnostic trouble codes. information on deleting diagnostic trouble codes.
3. Turn the key switch "OFF" for at least 10 sec. 3. Turn the key switch "OFF" for at least 10 sec.
4. Perform a test drive under the "Preconditions when 4. Perform a test drive under the "Preconditions when
diagnostic trouble code is set". diagnostic trouble code is set".
5. Confirm the diagnostic trouble code. 5. Confirm the diagnostic trouble code.

No Has a diagnostic trouble code: 2106 been No Has a diagnostic trouble code: 2106 been
detected? detected?

Yes Yes
Go to step 2. Go to step 2.

Step 12 Step 12
Check that no other diagnostic trouble code has been Check that no other diagnostic trouble code has been
detected. detected.

Has any other diagnostic trouble code been No Has any other diagnostic trouble code been No
Check repair. Check repair.
detected? detected?

Yes Yes

Go to diagnosis for each diagnostic trouble code. Go to diagnosis for each diagnostic trouble code.

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4021-212 4021-212
Block diagram Block diagram
CONTROLLER A CONTROLLER A

“CAN COMMUNICATION” “CAN COMMUNICATION”

Preconditions when DTC is set Preconditions when DTC is set


• DTC: 2104 is not detected. • DTC: 2104 is not detected.
• Key switch input power supply voltage is 20 V or higher. • Key switch input power supply voltage is 20 V or higher.
Diagnostic aid Diagnostic aid
If an intermittent problem is suspected, the cause may be one of the following. If an intermittent problem is suspected, the cause may be one of the following.
• Harness connector connection problem • Harness connector connection problem
• Harness routing problem • Harness routing problem
• Breakage in harness covering due to friction • Breakage in harness covering due to friction
• Wire disconnection within harness covering • Wire disconnection within harness covering
In order to detect these causes, the following inspection is necessary. In order to detect these causes, the following inspection is necessary.
• Harness connector and ECM connector connection problem • Harness connector and ECM connector connection problem
- Terminal has come out from connector - Terminal has come out from connector
- Connection between non-matching terminals - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem
• Harness damage • Harness damage
- Inspect the external appearance to check for any harness damage. - Inspect the external appearance to check for any harness damage.
- While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data - While moving the connector or harness related to a sensor, confirm the display of the related item in the scan tool data
display. The display change shows the trouble location. display. The display change shows the trouble location.

Breaker box inspection procedure Breaker box inspection procedure


For steps in which breaker box usage is indicated, perform inspection with the following procedure. For steps in which breaker box usage is indicated, perform inspection with the following procedure.
Return to diagnosis step after inspection. Return to diagnosis step after inspection.

Inspection Measurement terminal Normal Abnormal Inspection Measurement terminal Normal Abnormal
Step Inspection item Measurement condition Step Inspection item Measurement condition
method No. value value method No. value value
37-Computer A con- 37-Computer A con-
Resistance • Remove the computer Resistance • Remove the computer
Disconnection/ nector terminal 100 Ω or 10 M Ω or Disconnection/ nector terminal 100 Ω or 10 M Ω or
4 measure- A connector. 4 measure- A connector.
high resistance 18-Computer A con- lower higher high resistance 18-Computer A con- lower higher
ment • Key switch "OFF" ment • Key switch "OFF"
nector terminal nector terminal
Resistance • Remove the computer Resistance • Remove the computer
18- GND 10 Ω or 100 Ω or 18- GND 10 Ω or 100 Ω or
Short circuit with GND measure- A connector. Short circuit with GND measure- A connector.
37- GND higher lower 37- GND higher lower
ment • Key switch "OFF" ment • Key switch "OFF"
5 5
Voltage • Remove the computer Voltage • Remove the computer
Short circuit with power 18- GND 18 V or Short circuit with power 18- GND 18 V or
value mea- A connector. 0V value mea- A connector. 0V
supply 37- GND higher supply 37- GND higher
surement • Key switch "ON" surement • Key switch "ON"

Lep NST-10-06-001EN Issued 10-08 Lep NST-10-06-001EN Issued 10-08


4022

4022
Section Section
4022 4022

MAIN BODY ERROR CODE (DTC) MAIN BODY ERROR CODE (DTC)

Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B4022-0EN October 2008 CNH Lep SM130B4022-0EN October 2008
4022-2 4022-2
TABLE OF CONTENTS TABLE OF CONTENTS
DTC: 7000 DTC: 7000
P1 Pressure Sensor Signal Abnormality .................................................................................................................. 4 P1 Pressure Sensor Signal Abnormality .................................................................................................................. 4
DTC: 7001 DTC: 7001
P2 Pressure Sensor Signal Abnormality .................................................................................................................. 6 P2 Pressure Sensor Signal Abnormality .................................................................................................................. 6
DTC: 7002 DTC: 7002
N1 Pressure Sensor Signal Abnormality.................................................................................................................. 8 N1 Pressure Sensor Signal Abnormality.................................................................................................................. 8
DTC: 7003 DTC: 7003
N2 Pressure Sensor Signal Abnormality................................................................................................................ 10 N2 Pressure Sensor Signal Abnormality................................................................................................................ 10
DTC: 7004 DTC: 7004
Overload Pressure Sensor Signal Abnormality...................................................................................................... 12 Overload Pressure Sensor Signal Abnormality...................................................................................................... 12
DTC: 7005 DTC: 7005
Bottom Pressure Sensor Signal Abnormality ......................................................................................................... 14 Bottom Pressure Sensor Signal Abnormality ......................................................................................................... 14
DTC: 7006 DTC: 7006
Rod Pressure Sensor Signal Abnormality.............................................................................................................. 16 Rod Pressure Sensor Signal Abnormality.............................................................................................................. 16
DTC: 7020 DTC: 7020
Upper Pressure Sensor Signal Abnormality........................................................................................................... 18 Upper Pressure Sensor Signal Abnormality........................................................................................................... 18
DTC: 7021 DTC: 7021
Swing Pressure Sensor Signal Abnormality........................................................................................................... 20 Swing Pressure Sensor Signal Abnormality........................................................................................................... 20
DTC: 7022 DTC: 7022
Travel Pressure Sensor Signal Abnormality .......................................................................................................... 22 Travel Pressure Sensor Signal Abnormality .......................................................................................................... 22
DTC: 7040 DTC: 7040
Fuel Level Sensor Signal Abnormality ................................................................................................................... 24 Fuel Level Sensor Signal Abnormality ................................................................................................................... 24
DTC: 7041 DTC: 7041
Oil Temperature Sensor Signal Abnormality.......................................................................................................... 26 Oil Temperature Sensor Signal Abnormality.......................................................................................................... 26
DTC: 7045 DTC: 7045
Monitor Thermistor Signal Abnormality .................................................................................................................. 28 Monitor Thermistor Signal Abnormality .................................................................................................................. 28
DTC: 7060 DTC: 7060
Boom Angle Sensor Signal Abnormality ................................................................................................................ 29 Boom Angle Sensor Signal Abnormality ................................................................................................................ 29
DTC: 7061 DTC: 7061
Arm Angle Sensor Signal Abnormality ................................................................................................................... 31 Arm Angle Sensor Signal Abnormality ................................................................................................................... 31
DTC: 7063 DTC: 7063
Return Filter Clogging Pressure Switch Signal Abnormality .................................................................................. 33 Return Filter Clogging Pressure Switch Signal Abnormality .................................................................................. 33
DTC: 7200 DTC: 7200
Swing Brake Solenoid Signal Abnormality ............................................................................................................. 37 Swing Brake Solenoid Signal Abnormality ............................................................................................................. 37
DTC: 7201 DTC: 7201
Travel High-speed Solenoid Signal Abnormality.................................................................................................... 39 Travel High-speed Solenoid Signal Abnormality.................................................................................................... 39
DTC: 7202 DTC: 7202
Pressure Boost Solenoid Signal Abnormality......................................................................................................... 41 Pressure Boost Solenoid Signal Abnormality......................................................................................................... 41
DTC: 7203 DTC: 7203
Travel Alarm Buzzer Signal Abnormality................................................................................................................ 44 Travel Alarm Buzzer Signal Abnormality................................................................................................................ 44
DTC: 7209 DTC: 7209
Air Conditioner Coolant Temperature Signal Abnormality ..................................................................................... 46 Air Conditioner Coolant Temperature Signal Abnormality ..................................................................................... 46
DTC: 7210 DTC: 7210
Liftcrane Buzzer Signal Abnormality ...................................................................................................................... 47 Liftcrane Buzzer Signal Abnormality ...................................................................................................................... 47
Lep SM130B4022-0EN Issued 10-08 Lep SM130B4022-0EN Issued 10-08
4022-3 4022-3
DTC: 7211 DTC: 7211
Rotating Light, Bucket Lock Signal Abnormality .................................................................................................... 50 Rotating Light, Bucket Lock Signal Abnormality .................................................................................................... 50
DTC: 7240 DTC: 7240
Pump Horsepower Proportional Valve Signal Abnormality .................................................................................... 52 Pump Horsepower Proportional Valve Signal Abnormality .................................................................................... 52
DTC: 7241 DTC: 7241
P1 Flow Control Proportional Valve Signal Abnormality ........................................................................................ 55 P1 Flow Control Proportional Valve Signal Abnormality ........................................................................................ 55
DTC: DTC:
7400 Abnormally High Coolant Temperature (105 or higher) 7400 Abnormally High Coolant Temperature (105 or higher)
7402 Abnormally High Coolant Temperature (110 °C or higher) 7402 Abnormally High Coolant Temperature (110 °C or higher)
7403 Abnormally High Coolant Temperature (120 °C or higher) ........................................................................... 58 7403 Abnormally High Coolant Temperature (120 °C or higher) ........................................................................... 58
DTC: 7404 DTC: 7404
Abnormally High Oil Temperature (95 °C or higher) .............................................................................................. 59 Abnormally High Oil Temperature (95 °C or higher) .............................................................................................. 59
DTC: DTC:
7405 Abnormally High Boost Temperature (80 °C or higher) 7405 Abnormally High Boost Temperature (80 °C or higher)
7406 Abnormally High Boost Temperature (90 °C or higher) ................................................................................ 60 7406 Abnormally High Boost Temperature (90 °C or higher) ................................................................................ 60
DTC: 7420 DTC: 7420
Abnormally Low Alternator Voltage........................................................................................................................ 61 Abnormally Low Alternator Voltage........................................................................................................................ 61
DTC: 7421 DTC: 7421
Coolant Level Reduction ........................................................................................................................................ 63 Coolant Level Reduction ........................................................................................................................................ 63
DTC: 7422 DTC: 7422
Abnormally Low Engine Oil Pressure..................................................................................................................... 64 Abnormally Low Engine Oil Pressure..................................................................................................................... 64
DTC: 7423 DTC: 7423
Air Cleaner Clogging .............................................................................................................................................. 65 Air Cleaner Clogging .............................................................................................................................................. 65
DTC: 7424 DTC: 7424
Return Filter Clogging (breaker specifications) ...................................................................................................... 67 Return Filter Clogging (breaker specifications) ...................................................................................................... 67
DTC: 7600 DTC: 7600
CAN Bus Abnormality ............................................................................................................................................ 68 CAN Bus Abnormality ............................................................................................................................................ 68
DTC: 7601 DTC: 7601
Monitor Communication Abnormality ..................................................................................................................... 70 Monitor Communication Abnormality ..................................................................................................................... 70
DTC: 7602 DTC: 7602
ECM Communication Abnormality ......................................................................................................................... 71 ECM Communication Abnormality ......................................................................................................................... 71
DTC: 7605 DTC: 7605
ECM Mismatch....................................................................................................................................................... 72 ECM Mismatch....................................................................................................................................................... 72
DTC: 7606 DTC: 7606
EEPROM Data Abnormality ................................................................................................................................... 73 EEPROM Data Abnormality ................................................................................................................................... 73

Lep SM130B4022-0EN Issued 10-08 Lep SM130B4022-0EN Issued 10-08


4022-4 4022-4
DTC: 7000 DTC: 7000
P1 Pressure Sensor Signal Abnormality P1 Pressure Sensor Signal Abnormality

P1 pressure sensor signal abnormality P1 pressure sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7000 displayed. Diagnostic trouble code: 7000 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the P1 pressure sensor voltage on the No Check the P1 pressure sensor voltage on the No
service support screen. 0.25 V or lower service support screen. 0.25 V or lower
4.75 V or higher 4.75 V or higher

Yes Yes
CHK H / W-A 3 Pot4 0000 V CHK H / W-A 3 Pot4 0000 V

Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V

Pot2 0000 V Pot6 0000 V A Pot2 0000 V Pot6 0000 V A


Pot3 0000 V Pot7 0000 V Go to A. Pot3 0000 V Pot7 0000 V Go to A.

Inspect for shorts to power supply. Inspect for shorts to power supply.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.115. CN.115.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
W400 harness defect (short) W400 harness defect (short)
terminal 1 of the CN.115 harness side. terminal 1 of the CN.115 harness side.
Replacement Replacement
About 5 V About 5 V

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
Y420 harness defect (short) Y420 harness defect (short)
terminal 2 of the CN.115 harness side terminal 2 of the CN.115 harness side
Replacement Replacement
4.75 V or lower 4.75 V or lower

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
BW440 harness defect (short) BW440 harness defect (short)
terminal 3 of the CN.115 harness side. terminal 3 of the CN.115 harness side.
Replacement Replacement
0.25 V or lower 0.25 V or lower

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-5 4022-5

A A

Inspect the P1 pressure Inspect the P1 pressure


sensor. sensor.

Turn the key switch OFF and disconnect CN.115. Turn the key switch OFF and disconnect CN.115.

Cause and solution Cause and solution

Measure the resistance between terminals 1 No Measure the resistance between terminals 1 No
P1 pressure sensor defect P1 pressure sensor defect
and 3 of the CN.115 P1 pressure sensor side. and 3 of the CN.115 P1 pressure sensor side.
Replacement Replacement
About 10kΩ About 10kΩ

Yes Yes

Inspect for shorts to ground and Inspect for shorts to ground and
disconnections. disconnections.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 harness defect Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 harness defect
and terminal 1 of the CN.115 harness side. terminal 3 of the CN.115 harness side. (disconnection) and terminal 1 of the CN.115 harness side. terminal 3 of the CN.115 harness side. (disconnection)
Inspect the conductance between the ground Conductance Repair or replace Inspect the conductance between the ground Conductance Repair or replace
and terminal 2 of the CN.115 harness side. and terminal 2 of the CN.115 harness side.
Yes Yes
Conductance Conductance
Key switch ON Key switch ON
Yes Yes

Cause and solution Cause and solution

Cause and solution Measure the voltage between the ground and terminal No W400 harness defect Cause and solution Measure the voltage between the ground and terminal No W400 harness defect
1 of the CN.115 harness side. (disconnection) 1 of the CN.115 harness side. (disconnection)
About 5 V Repair or replace About 5 V Repair or replace
W400 or Y420 harness W400 or Y420 harness
defect (short) Yes defect (short) Yes
Replacement Replacement
Cause and solution Cause and solution

Measure the voltage between the ground and terminal No Y420 harness defect Measure the voltage between the ground and terminal No Y420 harness defect
2 of the CN.115 harness side. (disconnection) 2 of the CN.115 harness side. (disconnection)
0.25 V or higher Repair or replace 0.25 V or higher Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A CONTROLLER A

PRESS. SENSOR (P1) PRESS. SENSOR (P1)

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-6 4022-6
DTC: 7001 DTC: 7001
P2 Pressure Sensor Signal Abnormality P2 Pressure Sensor Signal Abnormality

P2 pressure sensor signal abnormality P2 pressure sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7001 displayed. Diagnostic trouble code: 7001 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the P2 pressure sensor voltage on the No Check the P2 pressure sensor voltage on the No
service support screen. 0.25 V or lower service support screen. 0.25 V or lower
4.75 V or higher 4.75 V or higher

CHK H / W-A 3 Pot4 0000 V Yes CHK H / W-A 3 Pot4 0000 V Yes

Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V

Pot2 0000 V Pot6 0000 V A Pot2 0000 V Pot6 0000 V A


Pot3 0000 V Pot7 0000 V Go to A. Pot3 0000 V Pot7 0000 V Go to A.

Inspect for shorts to power supply. Inspect for shorts to power supply.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.116. CN.116.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No W400 or W401 harness defect Measure the voltage between the ground and No W400 or W401 harness defect
terminal 1 of the CN.116 harness side. (short) terminal 1 of the CN.116 harness side. (short)
About 5 V Replacement About 5 V Replacement

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
L421 harness defect (short) L421 harness defect (short)
terminal 2 of the CN.116 harness side terminal 2 of the CN.116 harness side
Replacement Replacement
4.75 V or lower 4.75 V or lower

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No BW440 or BW441 harness Measure the voltage between the ground and No BW440 or BW441 harness
terminal 3 of the CN.116 harness side. defect (short) terminal 3 of the CN.116 harness side. defect (short)
0.25 V or lower Replacement 0.25 V or lower Replacement

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-7 4022-7

A A

Inspect the P2 pressure Inspect the P2 pressure


sensor. sensor.

Turn the key switch OFF and disconnect CN.116. Turn the key switch OFF and disconnect CN.116.

Cause and solution Cause and solution

Measure the resistance between terminals 1 No Measure the resistance between terminals 1 No
P2 pressure sensor defect P2 pressure sensor defect
and 3 of the CN.116 P2 pressure sensor side. and 3 of the CN.116 P2 pressure sensor side.
Replacement Replacement
About 10kΩ About 10kΩ

Yes Yes

Inspect for shorts to ground and Inspect for shorts to ground and
disconnections. disconnections.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW441 harness Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW441 harness
and terminal 1 of the CN.116 harness side. terminal 3 of the CN.116 harness side. defect (disconnection) and terminal 1 of the CN.116 harness side. terminal 3 of the CN.116 harness side. defect (disconnection)
Inspect the conductance between the ground Conductance Repair or replace Inspect the conductance between the ground Conductance Repair or replace
and terminal 2 of the CN.116 harness side. and terminal 2 of the CN.116 harness side.
Yes Yes
Conductance Conductance
Key switch ON Key switch ON
Yes Yes

Cause and solution Cause and solution

Cause and solution Measure the voltage between the ground and terminal No W400 or W401 harness Cause and solution Measure the voltage between the ground and terminal No W400 or W401 harness
1 of the CN.116 harness side. defect (disconnection) 1 of the CN.116 harness side. defect (disconnection)
About 5 V Repair or replace About 5 V Repair or replace
W400, W401 or L421 W400, W401 or L421
harness defect (short) Yes harness defect (short) Yes
Replacement Replacement
Cause and solution Cause and solution

Measure the voltage between the ground and terminal No L421 harness defect Measure the voltage between the ground and terminal No L421 harness defect
2 of the CN.116 harness side. (disconnection) 2 of the CN.116 harness side. (disconnection)
0.25 V or higher Repair or replace 0.25 V or higher Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A CONTROLLER A

PRESS. SENSOR (P2) PRESS. SENSOR (P2)

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-8 4022-8
DTC: 7002 DTC: 7002
N1 Pressure Sensor Signal Abnormality N1 Pressure Sensor Signal Abnormality

N1 pressure sensor signal abnormality N1 pressure sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7002 displayed. Diagnostic trouble code: 7002 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the N1 pressure sensor voltage on the No Check the N1 pressure sensor voltage on the No
service support screen. 0.25 V or lower service support screen. 0.25 V or lower
4.75 V or higher 4.75 V or higher

CHK H / W-A 3 Pot4 0000 V Yes CHK H / W-A 3 Pot4 0000 V Yes

Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V

Pot2 0000 V Pot6 0000 V A Pot2 0000 V Pot6 0000 V A


Pot3 0000 V Pot7 0000 V Go to A. Pot3 0000 V Pot7 0000 V Go to A.

Inspect for shorts to power supply. Inspect for shorts to power supply.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.117. CN.117.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No W400 or W402 harness defect Measure the voltage between the ground and No W400 or W402 harness defect
terminal 1 of the CN.117 harness side. (short) terminal 1 of the CN.117 harness side. (short)
About 5 V Replacement About 5 V Replacement

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
Lg422 harness defect (short) Lg422 harness defect (short)
terminal 2 of the CN.117 harness side terminal 2 of the CN.117 harness side
Replacement Replacement
4.75 V or lower 4.75 V or lower

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No BW440 or BW442 harness Measure the voltage between the ground and No BW440 or BW442 harness
terminal 3 of the CN.117 harness side. defect (short) terminal 3 of the CN.117 harness side. defect (short)
0.25 V or lower Replacement 0.25 V or lower Replacement

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-9 4022-9

A A

Inspect the N1 pressure Inspect the N1 pressure


sensor. sensor.

Turn the key switch OFF and disconnect CN.117. Turn the key switch OFF and disconnect CN.117.

Cause and solution Cause and solution

Measure the resistance between terminals 1 No Measure the resistance between terminals 1 No
N1 pressure sensor defect N1 pressure sensor defect
and 3 of the CN.117 N1 pressure sensor side. and 3 of the CN.117 N1 pressure sensor side.
Replacement Replacement
About 10 kΩ About 10 kΩ

Yes Yes

Inspect for shorts to ground and Inspect for shorts to ground and
disconnections. disconnections.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW442 harness Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW442 harness
and terminal 1 of the CN.117 harness side. terminal 3 of the CN.117 harness side. defect (disconnection) and terminal 1 of the CN.117 harness side. terminal 3 of the CN.117 harness side. defect (disconnection)
Inspect the conductance between the ground Conductance Repair or replace Inspect the conductance between the ground Conductance Repair or replace
and terminal 2 of the CN.117 harness side. and terminal 2 of the CN.117 harness side.
Yes Yes
Conductance Conductance
Key switch ON Key switch ON
Yes Yes

Cause and solution Cause and solution

Cause and solution Measure the voltage between the ground and terminal No W400 or W402 harness Cause and solution Measure the voltage between the ground and terminal No W400 or W402 harness
1 of the CN.117 harness side. defect (disconnection) 1 of the CN.117 harness side. defect (disconnection)
About 5 V Repair or replace About 5 V Repair or replace
W400, W402 or Lg422 W400, W402 or Lg422
harness defect (short) Yes harness defect (short) Yes
Replacement Replacement
Cause and solution Cause and solution

Measure the voltage between the ground and terminal No Lg422 harness defect Measure the voltage between the ground and terminal No Lg422 harness defect
2 of the CN.117 harness side. (disconnection) 2 of the CN.117 harness side. (disconnection)
0.25 V or higher Repair or replace 0.25 V or higher Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A CONTROLLER A

PRESS. SENSOR (N1) PRESS. SENSOR (N1)

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-10 4022-10
DTC: 7003 DTC: 7003
N2 Pressure Sensor Signal Abnormality N2 Pressure Sensor Signal Abnormality

N2 pressure sensor signal abnormality N2 pressure sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7003 displayed. Diagnostic trouble code: 7003 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the N2 pressure sensor voltage on the No Check the N2 pressure sensor voltage on the No
service support screen. 0.25 V or lower service support screen. 0.25 V or lower
4.75 V or higher 4.75 V or higher

CHK H / W-A 3 Pot4 0000 V Yes CHK H / W-A 3 Pot4 0000 V Yes

Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V

Pot2 0000 V Pot6 0000 V A Pot2 0000 V Pot6 0000 V A


Pot3 0000 V Pot7 0000 V Go to A. Pot3 0000 V Pot7 0000 V Go to A.

Inspect for shorts to power supply. Inspect for shorts to power supply.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.118. CN.118.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No W400 or W403 harness defect Measure the voltage between the ground and No W400 or W403 harness defect
terminal 1 of the CN.118 harness side. (short) terminal 1 of the CN.118 harness side. (short)
About 5 V Replacement About 5 V Replacement

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
Br423 harness defect (short) Br423 harness defect (short)
terminal 2 of the CN.118 harness side terminal 2 of the CN.118 harness side
Replacement Replacement
4.75 V or lower 4.75 V or lower

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No BW440 or BW443 harness Measure the voltage between the ground and No BW440 or BW443 harness
terminal 3 of the CN.118 harness side. defect (short) terminal 3 of the CN.118 harness side. defect (short)
0.25 V or lower Replacement 0.25 V or lower Replacement

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-11 4022-11

A A

Inspect the N2 pressure Inspect the N2 pressure


sensor. sensor.

Turn the key switch OFF and disconnect CN.118. Turn the key switch OFF and disconnect CN.118.

Cause and solution Cause and solution

Measure the resistance between terminals 1 No Measure the resistance between terminals 1 No
N2 pressure sensor defect N2 pressure sensor defect
and 3 of the CN.118 N2 pressure sensor side. and 3 of the CN.118 N2 pressure sensor side.
Replacement Replacement
About 10 kΩ About 10 kΩ

Yes Yes

Inspect for shorts to ground and Inspect for shorts to ground and
disconnections. disconnections.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW443 harness Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW443 harness
and terminal 1 of the CN.118 harness side. terminal 3 of the CN.118 harness side. defect (disconnection) and terminal 1 of the CN.118 harness side. terminal 3 of the CN.118 harness side. defect (disconnection)
Inspect the conductance between the ground Conductance Repair or replace Inspect the conductance between the ground Conductance Repair or replace
and terminal 2 of the CN.118 harness side. and terminal 2 of the CN.118 harness side.
Yes Yes
Conductance Conductance
Key switch ON Key switch ON
Yes Yes

Cause and solution Cause and solution

Cause and solution Measure the voltage between the ground and terminal No W400 or W403 harness Cause and solution Measure the voltage between the ground and terminal No W400 or W403 harness
1 of the CN.118 harness side. defect (disconnection) 1 of the CN.118 harness side. defect (disconnection)
About 5 V Repair or replace About 5 V Repair or replace
W400, W403 or Br423 W400, W403 or Br423
harness defect (short) Yes harness defect (short) Yes
Replacement Replacement
Cause and solution Cause and solution

Measure the voltage between the ground and terminal No Br423 harness defect Measure the voltage between the ground and terminal No Br423 harness defect
2 of the CN.118 harness side. (disconnection) 2 of the CN.118 harness side. (disconnection)
0.25 V or higher Repair or replace 0.25 V or higher Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A CONTROLLER A

PRESS. SENSOR (N2) PRESS. SENSOR (N2)

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-12 4022-12
DTC: 7004 DTC: 7004
Overload Pressure Sensor Signal Abnormality Overload Pressure Sensor Signal Abnormality

Overload pressure sensor signal abnormality Overload pressure sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7004 displayed. Diagnostic trouble code: 7004 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the overload pressure sensor voltage on No Check the overload pressure sensor voltage on No
the service support screen. 0.25 V or lower the service support screen. 0.25 V or lower
4.75 V or higher 4.75 V or higher

CHK H / W-A 4 Sn1 0000 V Yes CHK H / W-A 4 Sn1 0000 V Yes

Pot8 0000 V Sn2 0000 V Pot8 0000 V Sn2 0000 V

Pot9 0000 V Sn1 0000 Ω A Pot9 0000 V Sn1 0000 Ω A


Pot10 0000 V Sn2 0000 Ω Go to A. Pot10 0000 V Sn2 0000 Ω Go to A.

Inspect for shorts to power supply. Inspect for shorts to power supply.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.123. CN.123.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No W400 or W408 harness defect Measure the voltage between the ground and No W400 or W408 harness defect
terminal 1 of the CN.123 harness side. (short) terminal 1 of the CN.123 harness side. (short)
About 5 V Replacement About 5 V Replacement

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
Gr428 harness defect (short) Gr428 harness defect (short)
terminal 2 of the CN.123 harness side terminal 2 of the CN.123 harness side
Replacement Replacement
4.75 V or lower 4.75 V or lower

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No BW440 or BW448 harness Measure the voltage between the ground and No BW440 or BW448 harness
terminal 3 of the CN.123 harness side. defect (short) terminal 3 of the CN.123 harness side. defect (short)
0.25 V or lower Replacement 0.25 V or lower Replacement

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-13 4022-13

A A

Inspect the overload Inspect the overload


pressure sensor. pressure sensor.

Turn the key switch OFF and disconnect CN.123. Turn the key switch OFF and disconnect CN.123.

Cause and solution Cause and solution

Measure the resistance between terminals 1 and No Measure the resistance between terminals 1 and No
Overload pressure sensor defect Overload pressure sensor defect
3 of the CN.123 overload pressure sensor side. 3 of the CN.123 overload pressure sensor side.
Replacement Replacement
About 10 kΩ About 10 kΩ

Yes Yes

Inspect for shorts to ground and Inspect for shorts to ground and
disconnections. disconnections.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW448 harness Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW448 harness
and terminal 1 of the CN.123 harness side. terminal 3 of the CN.123 harness side. defect (disconnection) and terminal 1 of the CN.123 harness side. terminal 3 of the CN.123 harness side. defect (disconnection)
Inspect the conductance between the ground Conductance Repair or replace Inspect the conductance between the ground Conductance Repair or replace
and terminal 2 of the CN.123 harness side. and terminal 2 of the CN.123 harness side.
Yes Yes
Conductance Conductance
Key switch ON Key switch ON
Yes Yes

Cause and solution Cause and solution

Cause and solution Measure the voltage between the ground and terminal No W440 or W408 harness Cause and solution Measure the voltage between the ground and terminal No W440 or W408 harness
1 of the CN.123 harness side. defect (disconnection) 1 of the CN.123 harness side. defect (disconnection)
About 5 V Repair or replace About 5 V Repair or replace
W400, W408 or Gr428 W400, W408 or Gr428
harness defect (short) Yes harness defect (short) Yes
Replacement Replacement
Cause and solution Cause and solution

Measure the voltage between the ground and terminal No Gr428 harness defect Measure the voltage between the ground and terminal No Gr428 harness defect
2 of the CN.123 harness side. (disconnection) 2 of the CN.123 harness side. (disconnection)
0.25 V or higher Repair or replace 0.25 V or higher Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A CONTROLLER A

PRESS. SENSOR (HBCV) PRESS. SENSOR (HBCV)

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-14 4022-14
DTC: 7005 DTC: 7005
Bottom Pressure Sensor Signal Abnormality Bottom Pressure Sensor Signal Abnormality

Bottom pressure sensor signal abnormality Bottom pressure sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7005 displayed. Diagnostic trouble code: 7005 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the bottom pressure sensor voltage on the No Check the bottom pressure sensor voltage on the No
service support screen. 0.25 V or lower service support screen. 0.25 V or lower
4.75 V or higher 4.75 V or higher

Yes Yes
CHK H / W-A 3 Pot4 0000 V CHK H / W-A 3 Pot4 0000 V

Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V

Pot2 0000 V Pot6 0000 V A Pot2 0000 V Pot6 0000 V A


Pot3 0000 V Pot7 0000 V Go to A. Pot3 0000 V Pot7 0000 V Go to A.

Inspect for shorts to power supply. Inspect for shorts to power supply.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.CR9. CN.CR9.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
W414 harness defect (short) W414 harness defect (short)
terminal 1 of the CN.CR9 harness side. terminal 1 of the CN.CR9 harness side.
Replacement Replacement
About 5 V About 5 V

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
Y434 harness defect (short) Y434 harness defect (short)
terminal 2 of the CN.CR9 harness side terminal 2 of the CN.CR9 harness side
Replacement Replacement
4.75 V or lower 4.75 V or lower

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
BW454 harness defect (short) BW454 harness defect (short)
terminal 3 of the CN.CR9 harness side. terminal 3 of the CN.CR9 harness side.
Replacement Replacement
0.25 V or lower 0.25 V or lower

Yes Yes

Cause and solution Cause and solution

Computer B defect Computer B defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-15 4022-15

A A

Inspect the bottom pressure Inspect the bottom pressure


sensor. sensor.

Turn the key switch OFF and disconnect CN.CR9. Turn the key switch OFF and disconnect CN.CR9.

Cause and solution Cause and solution

Measure the resistance between terminals 1 and No Measure the resistance between terminals 1 and No
Bottom pressure sensor defect Bottom pressure sensor defect
3 of the CN.CR9 bottom pressure sensor side. 3 of the CN.CR9 bottom pressure sensor side.
Replacement Replacement
About 10 kΩ About 10 kΩ

Yes Yes

Inspect for shorts to ground and Inspect for shorts to ground and
disconnections. disconnections.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground and No BW454 harness defect Inspect the conductance between the ground No Inspect the conductance between the ground and No BW454 harness defect
and terminal 1 of the CN.CR9 harness side. terminal 3 of the CN.CR9 harness side. (disconnection) and terminal 1 of the CN.CR9 harness side. terminal 3 of the CN.CR9 harness side. (disconnection)
Inspect the conductance between the ground Conductance Repair or replace Inspect the conductance between the ground Conductance Repair or replace
and terminal 2 of the CN.CR9 harness side. and terminal 2 of the CN.CR9 harness side.
Yes Yes
Conductance Conductance
Key switch ON Key switch ON
Yes Yes

Cause and solution Cause and solution

Cause and solution Measure the voltage between the ground and terminal No W414 harness defect Cause and solution Measure the voltage between the ground and terminal No W414 harness defect
1 of the CN.CR9 harness side. (disconnection) 1 of the CN.CR9 harness side. (disconnection)
About 5 V Repair or replace About 5 V Repair or replace
W414, Y434 harness defect W414, Y434 harness defect
(short) Yes (short) Yes
Replacement Replacement
Cause and solution Cause and solution

Measure the voltage between the ground and terminal No Y434 harness defect Measure the voltage between the ground and terminal No Y434 harness defect
2 of the CN.CR9 harness side. (disconnection) 2 of the CN.CR9 harness side. (disconnection)
0.25 V or higher Repair or replace 0.25 V or higher Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer B defect Computer B defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER B CONTROLLER B

PRESS. SENSOR PRESS. SENSOR


BOOM BOTTOM BOOM BOTTOM

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-16 4022-16
DTC: 7006 DTC: 7006
Rod Pressure Sensor Signal Abnormality Rod Pressure Sensor Signal Abnormality

Rod pressure sensor signal abnormality Rod pressure sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7006 displayed. Diagnostic trouble code: 7006 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the rod pressure sensor voltage on the No Check the rod pressure sensor voltage on the No
service support screen. 0.25 V or lower service support screen. 0.25 V or lower
4.75 V or higher 4.75 V or higher

Yes Yes
CHK H / W-A 3 Pot4 0000 V CHK H / W-A 3 Pot4 0000 V

Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V

Pot2 0000 V Pot6 0000 V A Pot2 0000 V Pot6 0000 V A


Pot3 0000 V Pot7 0000 V Go to A. Pot3 0000 V Pot7 0000 V Go to A.

Inspect for shorts to power supply. Inspect for shorts to power supply.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.CR10. CN.CR10.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No W414 or W415 harness defect Measure the voltage between the ground and No W414 or W415 harness defect
terminal 1 of the CN.CR10 harness side. (short) terminal 1 of the CN.CR10 harness side. (short)
About 5 V Replacement About 5 V Replacement

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
L435 harness defect (short) L435 harness defect (short)
terminal 2 of the CN.CR10 harness side terminal 2 of the CN.CR10 harness side
Replacement Replacement
4.75 V or lower 4.75 V or lower

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No BW454 or BW455 harness Measure the voltage between the ground and No BW454 or BW455 harness
terminal 3 of the CN.CR10 harness side. defect (short) terminal 3 of the CN.CR10 harness side. defect (short)
0.25 V or lower Replacement 0.25 V or lower Replacement

Yes Yes

Cause and solution Cause and solution

Computer B defect Computer B defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-17 4022-17

A A

Inspect the rod pressure Inspect the rod pressure


sensor. sensor.

Turn the key switch OFF and disconnect CN.CR10. Turn the key switch OFF and disconnect CN.CR10.

Cause and solution Cause and solution

Measure the resistance between terminals 1 and No Measure the resistance between terminals 1 and No
Rod pressure sensor defect Rod pressure sensor defect
3 of the CN.CR10 bottom pressure sensor side. 3 of the CN.CR10 bottom pressure sensor side.
Replacement Replacement
About 10 kΩ About 10 kΩ

Yes Yes

Inspect for shorts to ground and Inspect for shorts to ground and
disconnections. disconnections.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground and No BW454 or BW455 harness Inspect the conductance between the ground No Inspect the conductance between the ground and No BW454 or BW455 harness
and terminal 1 of the CN.CR10 harness side. terminal 3 of the CN.CR10 harness side. defect (disconnection) and terminal 1 of the CN.CR10 harness side. terminal 3 of the CN.CR10 harness side. defect (disconnection)
Inspect the conductance between the ground Conductance Repair or replace Inspect the conductance between the ground Conductance Repair or replace
and terminal 2 of the CN.CR10 harness side. and terminal 2 of the CN.CR10 harness side.
Yes Yes
Conductance Conductance
Key switch ON Key switch ON
Yes Yes

Cause and solution Cause and solution

Cause and solution Measure the voltage between the ground and terminal No W414 or W415 harness Cause and solution Measure the voltage between the ground and terminal No W414 or W415 harness
1 of the CN.CR10 harness side. defect (disconnection) 1 of the CN.CR10 harness side. defect (disconnection)
About 5 V Repair or replace About 5 V Repair or replace
W414, W415 or L435 W414, W415 or L435
harness defect (short) Yes harness defect (short) Yes
Replacement Replacement
Cause and solution Cause and solution

Measure the voltage between the ground and terminal No L435 harness defect Measure the voltage between the ground and terminal No L435 harness defect
2 of the CN.CR10 harness side. (disconnection) 2 of the CN.CR10 harness side. (disconnection)
0.25 V or higher Repair or replace 0.25 V or higher Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer B defect Computer B defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER B CONTROLLER B

PRESS. SENSOR PRESS. SENSOR


BOOM ROD BOOM ROD

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-18 4022-18
DTC: 7020 DTC: 7020
Upper Pressure Sensor Signal Abnormality Upper Pressure Sensor Signal Abnormality

Upper pressure sensor signal abnormality Upper pressure sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7020 displayed. Diagnostic trouble code: 7020 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the upper pressure sensor voltage on the No Check the upper pressure sensor voltage on the No
service support screen. 0.25 V or lower service support screen. 0.25 V or lower
4.75 V or higher 4.75 V or higher

Yes Yes
CHK H / W-A 3 Pot4 0000 V CHK H / W-A 3 Pot4 0000 V

Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V

Pot2 0000 V Pot6 0000 V A Pot2 0000 V Pot6 0000 V A


Pot3 0000 V Pot7 0000 V Go to A. Pot3 0000 V Pot7 0000 V Go to A.

Inspect for shorts to power supply. Inspect for shorts to power supply.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.120. CN.120.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No W400 or W405 harness defect Measure the voltage between the ground and No W400 or W405 harness defect
terminal 1 of the CN.120 harness side. (short) terminal 1 of the CN.120 harness side. (short)
About 5 V Replacement About 5 V Replacement

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
V425 harness defect (short) V425 harness defect (short)
terminal 2 of the CN.120 harness side terminal 2 of the CN.120 harness side
Replacement Replacement
4.75 V or lower 4.75 V or lower

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No BW440 or BW445 harness Measure the voltage between the ground and No BW440 or BW445 harness
terminal 3 of the CN.120 harness side. defect (short) terminal 3 of the CN.120 harness side. defect (short)
0.25 V or lower Replacement 0.25 V or lower Replacement

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-19 4022-19

A A

Inspect the upper pressure Inspect the upper pressure


sensor. sensor.

Turn the key switch OFF and disconnect CN.120. Turn the key switch OFF and disconnect CN.120.

Cause and solution Cause and solution

Measure the resistance between terminals 1 and No Measure the resistance between terminals 1 and No
Upper pressure sensor defect Upper pressure sensor defect
3 of the CN.120 upper pressure sensor side. 3 of the CN.120 upper pressure sensor side.
Replacement Replacement
About 10 kΩ About 10 kΩ

Yes Yes

Inspect for shorts to ground and Inspect for shorts to ground and
disconnections. disconnections.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW445 harness Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW445 harness
and terminal 1 of the CN.120 harness side. terminal 3 of the CN.120 harness side. defect (disconnection) and terminal 1 of the CN.120 harness side. terminal 3 of the CN.120 harness side. defect (disconnection)
Inspect the conductance between the ground Conductance Repair or replace Inspect the conductance between the ground Conductance Repair or replace
and terminal 2 of the CN.120 harness side. and terminal 2 of the CN.120 harness side.
Yes Yes
Conductance Conductance
Key switch ON Key switch ON
Yes Yes

Cause and solution Cause and solution

Cause and solution Measure the voltage between the ground and terminal No W400 or W405 harness Cause and solution Measure the voltage between the ground and terminal No W400 or W405 harness
1 of the CN.120 harness side. defect (disconnection) 1 of the CN.120 harness side. defect (disconnection)
About 5 V Repair or replace About 5 V Repair or replace
W400, W405 or V425 W400, W405 or V425
harness defect (short) Yes harness defect (short) Yes
Replacement Replacement
Cause and solution Cause and solution

Measure the voltage between the ground and terminal No G425 harness defect Measure the voltage between the ground and terminal No G425 harness defect
2 of the CN.120 harness side. (disconnection) 2 of the CN.120 harness side. (disconnection)
0.25 V or higher Repair or replace 0.25 V or higher Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A CONTROLLER A

PRESS. SENSOR PRESS. SENSOR


(PILOT UPPER) (PILOT UPPER)

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-20 4022-20
DTC: 7021 DTC: 7021
Swing Pressure Sensor Signal Abnormality Swing Pressure Sensor Signal Abnormality

Swing pressure sensor signal abnormality Swing pressure sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7021 displayed. Diagnostic trouble code: 7021 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the swing pressure sensor voltage on the No Check the swing pressure sensor voltage on the No
service support screen. 0.25 V or lower service support screen. 0.25 V or lower
4.75 V or higher 4.75 V or higher

Yes Yes
CHK H / W-A 3 Pot4 0000 V CHK H / W-A 3 Pot4 0000 V

Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V

Pot2 0000 V Pot6 0000 V A Pot2 0000 V Pot6 0000 V A


Pot3 0000 V Pot7 0000 V Go to A. Pot3 0000 V Pot7 0000 V Go to A.

Inspect for shorts to power supply. Inspect for shorts to power supply.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.119. CN.119.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No W400 or W404 harness defect Measure the voltage between the ground and No W400 or W404 harness defect
terminal 1 of the CN.119 harness side. (short) terminal 1 of the CN.119 harness side. (short)
About 5 V Replacement About 5 V Replacement

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
G424 harness defect (short) G424 harness defect (short)
terminal 2 of the CN.119 harness side terminal 2 of the CN.119 harness side
Replacement Replacement
4.75 V or lower 4.75 V or lower

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No BW440 or BW444 harness Measure the voltage between the ground and No BW440 or BW444 harness
terminal 3 of the CN.119 harness side. defect (short) terminal 3 of the CN.119 harness side. defect (short)
0.25 V or lower Replacement 0.25 V or lower Replacement

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-21 4022-21

A A

Inspect the swing pressure Inspect the swing pressure


sensor. sensor.

Turn the key switch OFF and disconnect CN.119. Turn the key switch OFF and disconnect CN.119.

Cause and solution Cause and solution

Measure the resistance between terminals 1 and No Measure the resistance between terminals 1 and No
Swing pressure sensor defect Swing pressure sensor defect
3 of the CN.119 swing pressure sensor side. 3 of the CN.119 swing pressure sensor side.
Replacement Replacement
About 10 kΩ About 10 kΩ

Yes Yes

Inspect for shorts to ground and Inspect for shorts to ground and
disconnections. disconnections.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW444 harness Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW444 harness
and terminal 1 of the CN.119 harness side. terminal 3 of the CN.119 harness side. defect (disconnection) and terminal 1 of the CN.119 harness side. terminal 3 of the CN.119 harness side. defect (disconnection)
Inspect the conductance between the ground Conductance Repair or replace Inspect the conductance between the ground Conductance Repair or replace
and terminal 2 of the CN.119 harness side. and terminal 2 of the CN.119 harness side.
Yes Yes
Conductance Conductance
Key switch ON Key switch ON
Yes Yes

Cause and solution Cause and solution

Cause and solution Measure the voltage between the ground and terminal No W400 or W404 harness Cause and solution Measure the voltage between the ground and terminal No W400 or W404 harness
1 of the CN.119 harness side. defect (disconnection) 1 of the CN.119 harness side. defect (disconnection)
About 5 V Repair or replace About 5 V Repair or replace
W400, W404 or G424 W400, W404 or G424
harness defect (short) Yes harness defect (short) Yes
Replacement Replacement
Cause and solution Cause and solution

Measure the voltage between the ground and terminal No G424 harness defect Measure the voltage between the ground and terminal No G424 harness defect
2 of the CN.119 harness side. (disconnection) 2 of the CN.119 harness side. (disconnection)
0.25 V or higher Repair or replace 0.25 V or higher Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A CONTROLLER A

PRESS. SENSOR PRESS. SENSOR


(PILOT SWING) (PILOT SWING)

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-22 4022-22
DTC: 7022 DTC: 7022
Travel Pressure Sensor Signal Abnormality Travel Pressure Sensor Signal Abnormality

Travel pressure sensor signal abnormality Travel pressure sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7022 displayed. Diagnostic trouble code: 7022 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the travel pressure sensor voltage on the No Check the travel pressure sensor voltage on the No
service support screen. 0.25 V or lower service support screen. 0.25 V or lower
4.75 V or higher 4.75 V or higher

Yes Yes
CHK H / W-A 3 Pot4 0000 V CHK H / W-A 3 Pot4 0000 V

Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V

Pot2 0000 V Pot6 0000 V A Pot2 0000 V Pot6 0000 V A


Pot3 0000 V Pot7 0000 V Go to A. Pot3 0000 V Pot7 0000 V Go to A.

Inspect for shorts to power supply. Inspect for shorts to power supply.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.121. CN.121.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No W400 or W406 harness defect Measure the voltage between the ground and No W400 or W406 harness defect
terminal 1 of the CN.121 harness side. (short) terminal 1 of the CN.121 harness side. (short)
About 5 V Replacement About 5 V Replacement

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
YG426 harness defect (short) YG426 harness defect (short)
terminal 2 of the CN.121 harness side terminal 2 of the CN.121 harness side
Replacement Replacement
4.75 V or lower 4.75 V or lower

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No BW440 or BW446 harness Measure the voltage between the ground and No BW440 or BW446 harness
terminal 3 of the CN.121 harness side. defect (short) terminal 3 of the CN.121 harness side. defect (short)
0.25 V or lower Replacement 0.25 V or lower Replacement

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-23 4022-23

A A

Inspect the travel pressure Inspect the travel pressure


sensor. sensor.

Turn the key switch OFF and disconnect CN.121. Turn the key switch OFF and disconnect CN.121.

Cause and solution Cause and solution

Measure the resistance between terminals 1 and No Measure the resistance between terminals 1 and No
Travel pressure sensor defect Travel pressure sensor defect
3 of the CN.121 swing pressure sensor side. 3 of the CN.121 swing pressure sensor side.
Replacement Replacement
About 10 kΩ About 10 kΩ

Yes Yes

Inspect for shorts to ground and Inspect for shorts to ground and
disconnections. disconnections.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW446 harness Inspect the conductance between the ground No Inspect the conductance between the ground and No BW440 or BW446 harness
and terminal 1 of the CN.121 harness side. terminal 3 of the CN.121 harness side. defect (disconnection) and terminal 1 of the CN.121 harness side. terminal 3 of the CN.121 harness side. defect (disconnection)
Inspect the conductance between the ground Conductance Repair or replace Inspect the conductance between the ground Conductance Repair or replace
and terminal 2 of the CN.121 harness side. and terminal 2 of the CN.121 harness side.
Yes Yes
Conductance Conductance
Key switch ON Key switch ON
Yes Yes

Cause and solution Cause and solution

Cause and solution Measure the voltage between the ground and terminal No W400 or W406 harness Cause and solution Measure the voltage between the ground and terminal No W400 or W406 harness
1 of the CN.121 harness side. defect (disconnection) 1 of the CN.121 harness side. defect (disconnection)
About 5 V Repair or replace About 5 V Repair or replace
W400, W406 or YG426 W400, W406 or YG426
harness defect (short) Yes harness defect (short) Yes
Replacement Replacement
Cause and solution Cause and solution

Measure the voltage between the ground and terminal No YG426 harness defect Measure the voltage between the ground and terminal No YG426 harness defect
2 of the CN.121 harness side. (disconnection) 2 of the CN.121 harness side. (disconnection)
0.25 V or higher Repair or replace 0.25 V or higher Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A CONTROLLER A

PRESS. SENSOR PRESS. SENSOR


(PILOT TRAVEL) (PILOT TRAVEL)

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-24 4022-24
DTC: 7040 DTC: 7040
Fuel Level Sensor Signal Abnormality Fuel Level Sensor Signal Abnormality

Fuel level sensor signal abnormality Fuel level sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7040 displayed. Diagnostic trouble code: 7040 displayed.

Inspect the connection status of each Inspect the connection status of each
connector and ground. connector and ground.

Check the fuel level sensor resistance on the No Check the fuel level sensor resistance on the No
service support screen. 2Ω or lower service support screen. 2Ω or lower
100Ω or higher 100Ω or higher

Yes Yes
CHK H / W-A 3 Sn1 0000 V CHK H / W-A 3 Sn1 0000 V

Pot8 0000 V Sn2 0000 V Pot8 0000 V Sn2 0000 V

Pot9 0000 V Sn1 0000 V A Pot9 0000 V Sn1 0000 V A


Pot10 0000 V Sn2 0000 V Go to A. Pot10 0000 V Sn2 0000 V Go to A.

Inspect for disconnection. Inspect for disconnection.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.135. Cause and solution CN.135. Cause and solution

Measure the resistance between terminals 1 and No Measure the resistance between terminals 1 and No
2 of the CN.135 fuel level sensor side. Fuel level sensor defect 2 of the CN.135 fuel level sensor side. Fuel level sensor defect
(See the Float position and resistance table.) Replacement (See the Float position and resistance table.) Replacement
This is the reference value. This is the reference value.

Yes Yes

Cause and solution Cause and solution

Inspect the conductance between the ground and No BG660 or BG600 harness defect Inspect the conductance between the ground and No BG660 or BG600 harness defect
terminal 1 of the CN.135 harness side. (disconnection) terminal 1 of the CN.135 harness side. (disconnection)
Conductance Repair or replace Conductance Repair or replace

Yes Yes
Key switch ON Key switch ON
Cause and solution Cause and solution

Measure the voltage between the ground and No GL412 harness defect Measure the voltage between the ground and No GL412 harness defect
terminal 2 of the CN.135 harness side. (disconnection) terminal 2 of the CN.135 harness side. (disconnection)
About 5 V Repair or replace About 5 V Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-25 4022-25

A A

Inspect for shorts. Inspect for shorts.

Turn the key switch OFF and connect Turn the key switch OFF and connect
CN.135. CN.135.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground No
GL412 harness defect (short) GL412 harness defect (short)
and terminal 2 of the CN.135 harness side. and terminal 2 of the CN.135 harness side.
Replacement Replacement
No conductance No conductance

Yes Yes

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No BG660 or BG600 harness defect Measure the voltage between the ground and No BG660 or BG600 harness defect
terminal 1 of the CN.135 harness side. (short) terminal 1 of the CN.135 harness side. (short)
0V Replacement 0V Replacement

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A CONTROLLER A

FUEL LEVEL FUEL LEVEL


SENSOR SENSOR

Float position and resistance Float position and resistance

Float position FULL HALF EMPTY Float position FULL HALF EMPTY

10 80 10 80
Resistance (Ω) 38 Resistance (Ω) 38
(tolerance of 0 to -4) (tolerance of 0 to 10) (tolerance of 0 to -4) (tolerance of 0 to 10)

* Temperature conditions: 20±15 °C * Temperature conditions: 20±15 °C

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-26 4022-26
DTC: 7041 DTC: 7041
Oil Temperature Sensor Signal Abnormality Oil Temperature Sensor Signal Abnormality

Oil temperature sensor signal abnormality Oil temperature sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7041 displayed. Diagnostic trouble code: 7041 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the oil temperature sensor resistance No Check the oil temperature sensor resistance No
(or voltage) on the service support screen. 111Ω (0.5V) or lower (or voltage) on the service support screen. 111Ω (0.5V) or lower
67200Ω (4.93 V) or higher 67200Ω (4.93 V) or higher

Yes Yes
CHK H / W-A 3 Sn1 0000 V CHK H / W-A 3 Sn1 0000 V

Pot8 0000 V Sn2 0000 V Pot8 0000 V Sn2 0000 V

Pot9 0000 V Sn1 0000 V A Pot9 0000 V Sn1 0000 V A


Pot10 0000 V Sn2 0000 V Go to A. Pot10 0000 V Sn2 0000 V Go to A.

Inspect for disconnection. Inspect for disconnection.

Turn the key switch OFF and disconnect Yes Turn the key switch OFF and disconnect Yes
CN.125. Cause and solution CN.125. Cause and solution

Measure the resistance between terminals 1 and No Measure the resistance between terminals 1 and No
2 of the CN.125 fuel level sensor side. Fuel level sensor defect 2 of the CN.125 fuel level sensor side. Fuel level sensor defect
(See the Float position and resistance table.) Replacement (See the Float position and resistance table.) Replacement
This is the reference value. This is the reference value.

Yes Yes

Cause and solution Cause and solution

Inspect the conductance between the ground and No BG451 or BG440 harness defect Inspect the conductance between the ground and No BG451 or BG440 harness defect
terminal 1 of the CN.125 harness side. (disconnection) terminal 1 of the CN.125 harness side. (disconnection)
Conductance Repair or replace Conductance Repair or replace

Yes Yes
Key switch ON Key switch ON
Cause and solution Cause and solution

Measure the voltage between the ground and No BrW411 harness defect Measure the voltage between the ground and No BrW411 harness defect
terminal 2 of the CN.125 harness side. (disconnection) terminal 2 of the CN.125 harness side. (disconnection)
About 5 V Repair or replace About 5 V Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-27 4022-27

A A

Inspect for shorts. Inspect for shorts.

Turn the key switch OFF and connect Turn the key switch OFF and connect
CN.125. CN.125.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground No
BrW411 harness defect (short) BrW411 harness defect (short)
and terminal 2 of the CN.125 harness side. and terminal 2 of the CN.125 harness side.
Replacement Replacement
No conductance No conductance

Yes Yes

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No BW451 or BW440 harness Measure the voltage between the ground and No BW451 or BW440 harness
terminal 1 of the CN.125 harness side. defect (short) terminal 1 of the CN.125 harness side. defect (short)
0V Replacement 0V Replacement

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A CONTROLLER A

HYD. OIL TEMP SENSOR HYD. OIL TEMP SENSOR

Oil temperature and resistance Oil temperature and resistance

Oil temperature (°C) -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 Oil temperature (°C) -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120

Resistance (Ω) 25400 15040 9160 5740 3700 2450 1660 1150 811 584 428 318 240 184 142 111 Resistance (Ω) 25400 15040 9160 5740 3700 2450 1660 1150 811 584 428 318 240 184 142 111

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-28 4022-28
DTC: 7045 DTC: 7045
Monitor Thermistor Signal Abnormality Monitor Thermistor Signal Abnormality

Monitor thermistor defect Monitor thermistor defect

Key switch ON Key switch ON

Diagnostic trouble code: Diagnostic trouble code:



7045 ( ) is displayed on the •
7045 ( ) is displayed on the
service support DIAG service support DIAG
screen. screen.

Cause and solution Cause and solution

Monitor defect Monitor defect


Replacement* Replacement*

*: Contrast correction is performed when the monitor thermistor is at an extremely high or low temperature. *: Contrast correction is performed when the monitor thermistor is at an extremely high or low temperature.
Even if the monitor thermistor has a defect, there is a correction function inside the monitor, so the monitor Even if the monitor thermistor has a defect, there is a correction function inside the monitor, so the monitor
thermistor does not need to be replaced if the monitor contrast is not significantly affected. thermistor does not need to be replaced if the monitor contrast is not significantly affected.

Block diagram Block diagram

CONTROLLER A MONITOR CONTROLLER A MONITOR

“SERIAL COMMUNICATION” “SERIAL COMMUNICATION”

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-29 4022-29
DTC: 7060 DTC: 7060
Boom Angle Sensor Signal Abnormality Boom Angle Sensor Signal Abnormality

Boom angle sensor signal abnormality Boom angle sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7060 displayed. Diagnostic trouble code: 7060 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the boom angle sensor voltage on the Check the boom angle sensor voltage on the
service support screen. 0.2 V or lower service support screen. 0.2 V or lower
4.8 V or higher 4.8 V or higher

CHK H / W-A 3 Pot4 0000 V CHK H / W-A 3 Pot4 0000 V

Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V

Pot2 0000 V Pot6 0000 V A Pot2 0000 V Pot6 0000 V A


Pot3 0000 V Pot7 0000 V Go to A. Pot3 0000 V Pot7 0000 V Go to A.

Inspect for shorts to power supply. Inspect for shorts to power supply.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.11. CN.11.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No BW414 or BW441 harness Measure the voltage between the ground and No BW414 or BW441 harness
terminal 3 of the CN.11 harness side. defect (short) terminal 3 of the CN.11 harness side. defect (short)
About 5 V Replacement About 5 V Replacement

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
Lg436 harness defect (short) Lg436 harness defect (short)
terminal 2 of the CN.11 harness side terminal 2 of the CN.11 harness side
Replacement Replacement
4.8 V or lower 4.8 V or lower

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No BW454 or BW456 harness Measure the voltage between the ground and No BW454 or BW456 harness
terminal 1 of the CN.11 harness side. defect (short) terminal 1 of the CN.11 harness side. defect (short)
0.2 V or lower Replacement 0.2 V or lower Replacement

Yes Yes

Cause and solution Cause and solution

Computer B defect Computer B defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-30 4022-30

A A

Check the boom angle Check the boom angle


sensor sensor

Turn the key switch OFF and disconnect CN.11. Turn the key switch OFF and disconnect CN.11.

Cause and solution Cause and solution

Measure the resistance between terminals 1 and No Check the Boom Angle Sensor Measure the resistance between terminals 1 and No Check the Boom Angle Sensor
3 of the CN.11 the boom angle sensor side. defect 3 of the CN.11 the boom angle sensor side. defect
About 10 kΩ Replacement About 10 kΩ Replacement

Yes Yes

Inspect for shorts to ground and Inspect for shorts to ground and
disconnections. disconnections.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground and No BW454 or BW456 harness Inspect the conductance between the ground No Inspect the conductance between the ground and No BW454 or BW456 harness
and terminal 3 of the CN.11 harness side. terminal 1 of the CN.11 harness side. defect (disconnection) and terminal 3 of the CN.11 harness side. terminal 1 of the CN.11 harness side. defect (disconnection)
Inspect the conductance between the ground Conductance Repair or replace Inspect the conductance between the ground Conductance Repair or replace
and terminal 2 of the CN.11 harness side. and terminal 2 of the CN.11 harness side.
Yes Yes
Conductance Conductance
Key switch ON Key switch ON
Yes Yes

Cause and solution Cause and solution

Cause and solution Measure the voltage between the ground and terminal No W414 or W416 harness Cause and solution Measure the voltage between the ground and terminal No W414 or W416 harness
3 of the CN.11 harness side. defect (disconnection) 3 of the CN.11 harness side. defect (disconnection)
About 5 V Repair or replace About 5 V Repair or replace
W414, W416 or Lg436 W414, W416 or Lg436
harness defect (short) Yes harness defect (short) Yes
Replacement Replacement
Cause and solution Cause and solution

Measure the voltage between the ground and terminal No Lg436 harness defect Measure the voltage between the ground and terminal No Lg436 harness defect
2 of the CN.11 harness side. (disconnection) 2 of the CN.11 harness side. (disconnection)
0.25 V or higher Repair or replace 0.25 V or higher Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer B defect Computer B defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER B ANGLE SENSOR BOOM CONTROLLER B ANGLE SENSOR BOOM

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-31 4022-31
DTC: 7061 DTC: 7061
Arm Angle Sensor Signal Abnormality Arm Angle Sensor Signal Abnormality

Arm angle sensor signal abnormality Arm angle sensor signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7061 displayed. Diagnostic trouble code: 7061 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Check the arm angle sensor voltage on the No Check the arm angle sensor voltage on the No
service support screen. 0.2 V or lower service support screen. 0.2 V or lower
4.8 V or higher 4.8 V or higher

Yes Yes
CHK H / W-A 3 Pot4 0000 V CHK H / W-A 3 Pot4 0000 V

Pot1 0000 V Pot5 0000 V Pot1 0000 V Pot5 0000 V

Pot2 0000 V Pot6 0000 V A Pot2 0000 V Pot6 0000 V A


Pot3 0000 V Pot7 0000 V Go to A. Pot3 0000 V Pot7 0000 V Go to A.

Inspect for shorts to power supply. Inspect for shorts to power supply.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.12. CN.12.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No BW457 or BW414 harness Measure the voltage between the ground and No BW457 or BW414 harness
terminal 3 of the CN.12 harness side. defect (short) terminal 3 of the CN.12 harness side. defect (short)
About 5 V Replacement About 5 V Replacement

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
Lg437 harness defect (short) Lg437 harness defect (short)
terminal 2 of the CN.12 harness side terminal 2 of the CN.12 harness side
Replacement Replacement
4.8 V or lower 4.8 V or lower

Yes Yes

Cause and solution Cause and solution

Measure the voltage between the ground and No BW454 or BW417 harness Measure the voltage between the ground and No BW454 or BW417 harness
terminal 1 of the CN.12 harness side. defect (short) terminal 1 of the CN.12 harness side. defect (short)
0.2 V or lower Replacement 0.2 V or lower Replacement

Yes Yes

Cause and solution Cause and solution

Computer B defect Computer B defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-32 4022-32

A A

Check the arm angle sensor Check the arm angle sensor

Turn the key switch OFF and disconnect CN.11. Turn the key switch OFF and disconnect CN.11.

Cause and solution Cause and solution

Measure the resistance between terminals 1 and No Check the Arm Angle Sensor Measure the resistance between terminals 1 and No Check the Arm Angle Sensor
3 of the CN.12 the arm angle sensor side. defect 3 of the CN.12 the arm angle sensor side. defect
About 10kΩ Replacement About 10kΩ Replacement

Yes Yes

Inspect for shorts to ground and Inspect for shorts to ground and
disconnections. disconnections.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground and No BW454 or BW417 harness Inspect the conductance between the ground No Inspect the conductance between the ground and No BW454 or BW417 harness
and terminal 1 of the CN.12 harness side. terminal 3 of the CN.12 harness side. defect (disconnection) and terminal 1 of the CN.12 harness side. terminal 3 of the CN.12 harness side. defect (disconnection)
Inspect the conductance between the ground Conductance Repair or replace Inspect the conductance between the ground Conductance Repair or replace
and terminal 2 of the CN.12 harness side. and terminal 2 of the CN.12 harness side.
Yes Yes
Conductance Conductance
Key switch ON Key switch ON
Yes Yes

Cause and solution Cause and solution

Cause and solution Measure the voltage between the ground and terminal No W414 or W414 harness Cause and solution Measure the voltage between the ground and terminal No W414 or W414 harness
1 of the CN.12 harness side. defect (disconnection) 1 of the CN.12 harness side. defect (disconnection)
About 5 V Repair or replace About 5 V Repair or replace
W457, W414 or Lg437 W457, W414 or Lg437
harness defect (short) Yes harness defect (short) Yes
Replacement Replacement
Cause and solution Cause and solution

Measure the voltage between the ground and terminal No Lg437 harness defect Measure the voltage between the ground and terminal No Lg437 harness defect
2 of the CN.12 harness side. (disconnection) 2 of the CN.12 harness side. (disconnection)
0.2 V or higher Repair or replace 0.2 V or higher Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer B defect Computer B defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER B CONTROLLER B

ANGLE SENSOR ARM ANGLE SENSOR ARM

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-33 4022-33
DTC: 7063 DTC: 7063
Return Filter Clogging Pressure Switch Signal Abnormality Return Filter Clogging Pressure Switch Signal Abnormality
(Breaker specifications) (Breaker specifications)

Return filter clogging pressure switch signal Return filter clogging pressure switch signal
abnormality abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7063 displayed. Diagnostic trouble code: 7063 displayed.

Inspect the connection status of Inspect the connection status of


each connector and ground. each connector and ground.

Inspect the return filter clogging pressure switch Inspect the return filter clogging pressure switch
switch. switch.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.134. disconnect CN.134.

Cause and solution Cause and solution


Inspect the conductance between terminals 1 Inspect the conductance between terminals 1
and 2 of the CN.134 return filter clogging No Return filter clogging pressure switch defect and 2 of the CN.134 return filter clogging No Return filter clogging pressure switch defect
pressure switch side. Replacement pressure switch side. Replacement
Conductance Conductance

Yes Yes

Inspect for Inspect for


disconnection. disconnection.

Cause and solution Cause and solution

Inspect the conductance between the ground and No BG663 harness defect Inspect the conductance between the ground and No BG663 harness defect
terminal 1 of the CN.134 harness side. (disconnection) terminal 1 of the CN.134 harness side. (disconnection)
Conductance Repair or replace Conductance Repair or replace

Yes Yes

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No YL472 harness defect Measure the voltage between the ground and No YL472 harness defect
terminal 2 of the CN.134 harness side. (disconnection) terminal 2 of the CN.134 harness side. (disconnection)
About 5 V Repair or replace About 5 V Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-34 4022-34

Block diagram Block diagram


CONTROLLER A CONTROLLER A

PRESS. SWITCH PRESS. SWITCH


(FILTER INDICATOR) (FILTER INDICATOR)

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-35 4022-35
(Other than breaker specifications) (Other than breaker specifications)

Return filter clogging pressure switch signal Return filter clogging pressure switch signal
abnormality abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7063 displayed. Diagnostic trouble code: 7063 displayed.

Inspect the connection status of Inspect the connection status of


each connector and ground. each connector and ground.

Inspect for disconnection Inspect for disconnection

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.134. disconnect CN.134.

Cause and solution Cause and solution


Inspect the conductance between terminals 1 No Inspect the conductance between terminals 1 No
Jump harness defect (disconnection) Jump harness defect (disconnection)
and 2 of the CN.134 jump harness side. and 2 of the CN.134 jump harness side.
Repair or replace Repair or replace
Conductance Conductance

Yes Yes

Cause and solution Cause and solution

Inspect the conductance between the ground and No BG663 harness defect Inspect the conductance between the ground and No BG663 harness defect
terminal 1 of the CN.134 harness side. (disconnection) terminal 1 of the CN.134 harness side. (disconnection)
Conductance Repair or replace Conductance Repair or replace

Yes Yes

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No YL472 harness defect Measure the voltage between the ground and No YL472 harness defect
terminal 2 of the CN.134 harness side. (disconnection) terminal 2 of the CN.134 harness side. (disconnection)
About 5 V Repair or replace About 5 V Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-36 4022-36

Block diagram Block diagram

CONTROLLER A CONTROLLER A

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-37 4022-37
DTC: 7200 DTC: 7200
Swing Brake Solenoid Signal Abnormality Swing Brake Solenoid Signal Abnormality

Swing brake solenoid signal abnormality Swing brake solenoid signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7200 displayed. Diagnostic trouble code: 7200 displayed.

Inspect the connection status of Inspect the connection status of


each connector. each connector.

Inspect the fusible link F1 (65A) fuse Inspect the fusible link F1 (65A) fuse
and fuse box F13 (10A) fuse to see and fuse box F13 (10A) fuse to see
if either is blown. if either is blown.

Inspect the swing brake solenoid. Inspect the swing brake solenoid.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.128. disconnect CN.128.

Cause and solution Cause and solution


Measure the resistance between terminals 1 No Measure the resistance between terminals 1 No
Swing brake solenoid defect Swing brake solenoid defect
and 2 of the CN.128 swing brake solenoid side. and 2 of the CN.128 swing brake solenoid side.
Replacement Replacement
34 Ω-47 Ω 34 Ω-47 Ω

Yes Yes

Inspect for shorts. Inspect for shorts.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
VG800 harness defect (short) VG800 harness defect (short)
terminal 2 of the CN.128 harness side. terminal 2 of the CN.128 harness side.
Replacement Replacement
0V 0V

Yes Yes

Key switch OFF Key switch OFF

Cause and solution Cause and solution

Inspect the conductance between the ground No R251, GR250, R109, R106, or Inspect the conductance between the ground No R251, GR250, R109, R106, or
and terminal 1 of the CN.128 harness side. R105 harness defect (short) and terminal 1 of the CN.128 harness side. R105 harness defect (short)
No conductance Replacement No conductance Replacement

Yes Yes

Inspect for Inspect for


disconnection. disconnection.

A A
Go to A. Go to A.

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-38 4022-38

A A
Cause and solution Cause and solution

Inspect whether there is conductance between the No VG800 harness defect Inspect whether there is conductance between the No VG800 harness defect
ground and terminal 2 of the CN.128 harness side. (disconnection) ground and terminal 2 of the CN.128 harness side. (disconnection)
Conductance Repair or replace Conductance Repair or replace

Yes Yes

Key switch ON Key switch ON

Cause and solution Cause and solution

No R251, GR250, R109, R106, or No R251, GR250, R109, R106, or


Measure the voltage between the ground and Measure the voltage between the ground and
R105 harness defect R105 harness defect
terminal 1 of the CN.128 harness side. terminal 1 of the CN.128 harness side.
(disconnection) (disconnection)
About 24 V About 24 V
Repair or replace Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram


CONTROLLER A CONTROLLER A
PRESS. SENSOR PRESS. SENSOR
(PILOT SWING) (PILOT SWING)

PRESS. SENSOR PRESS. SENSOR


(PILOT UPPER) (PILOT UPPER)

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

“CAN COMMUNICATION” FUSE F5 ( CONT) “CAN COMMUNICATION” FUSE F5 ( CONT)


ENGINE ENGINE
CONTROLLER CONTROLLER

FUSE F3 ( KEY) FUSE F3 ( KEY)

KEY SWITCH KEY SWITCH

RELAY BATTERY RELAY BATTERY


BATTERY (24 V) BATTERY (24 V)

FUSIBLE LINK FUSIBLE LINK

BOX FUSE BOX FUSE

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-39 4022-39
DTC: 7201 DTC: 7201
Travel High-speed Solenoid Signal Abnormality Travel High-speed Solenoid Signal Abnormality

Travel high-speed solenoid signal abnormality Travel high-speed solenoid signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7201 displayed. Diagnostic trouble code: 7201 displayed.

Inspect the connection status of Inspect the connection status of


each connector. each connector.

Inspect the fusible link F1 (65A) fuse Inspect the fusible link F1 (65A) fuse
and fuse box F13 (10A) fuse to see and fuse box F13 (10A) fuse to see
if either is blown. if either is blown.

Inspect the travel high-speed solenoid. Inspect the travel high-speed solenoid.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.129. disconnect CN.129.

Cause and solution Cause and solution


Measure the resistance between terminals 1 Measure the resistance between terminals 1
No Travel high-speed solenoid No Travel high-speed solenoid
and 2 of the CN.129 travel high-speed solenoid and 2 of the CN.129 travel high-speed solenoid
defect defect
side. side.
Replacement Replacement
34 Ω-47 Ω 34 Ω-47 Ω

Yes Yes

Inspect for shorts. Inspect for shorts.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
LG801 harness defect (short) LG801 harness defect (short)
terminal 2 of the CN.129 harness side. terminal 2 of the CN.129 harness side.
Replacement Replacement
0V 0V

Yes Yes

Key switch OFF Key switch OFF

Cause and solution Cause and solution

Inspect the conductance between the ground No R252, GR250, R109, R106, or Inspect the conductance between the ground No R252, GR250, R109, R106, or
and terminal 1 of the CN.129 harness side. R105 harness defect (short) and terminal 1 of the CN.129 harness side. R105 harness defect (short)
No conductance Replacement No conductance Replacement

Yes Yes

Inspect for Inspect for


disconnection. disconnection.

A A
Go to A. Go to A.

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-40 4022-40

A A
Cause and solution Cause and solution

Inspect whether there is conductance between the No LG801 harness defect Inspect whether there is conductance between the No LG801 harness defect
ground and terminal 2 of the CN.129 harness side. (disconnection) ground and terminal 2 of the CN.129 harness side. (disconnection)
Conductance Repair or replace Conductance Repair or replace

Yes Yes

Key switch ON Key switch ON

Cause and solution Cause and solution

No R252, GR250, R109, R106, or No R252, GR250, R109, R106, or


Measure the voltage between the ground and Measure the voltage between the ground and
R105 harness defect R105 harness defect
terminal 1 of the CN.129 harness side. terminal 1 of the CN.129 harness side.
(disconnection) (disconnection)
About 24 V About 24 V
Repair or replace Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram


CONTROLLER A CONTROLLER A
PRESS. SENSOR PRESS. SENSOR
(PILOT TRAVEL) (PILOT TRAVEL)

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

“CAN COMMUNICATION” FUSE F5 ( CONT) “CAN COMMUNICATION” FUSE F5 ( CONT)


ENGINE ENGINE
CONTROLLER CONTROLLER

FUSE F3 ( KEY) FUSE F3 ( KEY)

KEY SWITCH KEY SWITCH

RELAY BATTERY RELAY BATTERY


BATTERY (24 V) BATTERY (24 V)

FUSIBLE LINK FUSIBLE LINK

BOX FUSE BOX FUSE

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-41 4022-41
DTC: 7202 DTC: 7202
Pressure Boost Solenoid Signal Abnormality Pressure Boost Solenoid Signal Abnormality

Pressure boost solenoid signal abnormality Pressure boost solenoid signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7202 displayed. Diagnostic trouble code: 7202 displayed.

Inspect the connection status of Inspect the connection status of


each connector. each connector.

Inspect the fusible link F1 (65A) fuse Inspect the fusible link F1 (65A) fuse
and fuse box F13 (10A) fuse to see and fuse box F13 (10A) fuse to see
if either is blown. if either is blown.

Inspect the pressure boost solenoid. Inspect the pressure boost solenoid.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.130. disconnect CN.130.

Cause and solution Cause and solution


Measure the resistance between terminals 1 Measure the resistance between terminals 1
and 2 of the CN.130 travel high-speed solenoid No Pressure boost solenoid defect and 2 of the CN.130 travel high-speed solenoid No Pressure boost solenoid defect
side. Replacement side. Replacement
34 Ω-447 Ω 34 Ω-447 Ω

Yes Yes

Inspect for shorts. Inspect for shorts.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
YG802 harness defect (short) YG802 harness defect (short)
terminal 2 of the CN.130 harness side. terminal 2 of the CN.130 harness side.
Replacement Replacement
0V 0V

Yes Yes

Key switch OFF Key switch OFF

Cause and solution Cause and solution

Inspect the conductance between the ground No R253, GR250, R109, R106, or Inspect the conductance between the ground No R253, GR250, R109, R106, or
and terminal 1 of the CN.130 harness side. R105 harness defect (short) and terminal 1 of the CN.130 harness side. R105 harness defect (short)
No conductance Replacement No conductance Replacement

Yes Yes

Inspect for Inspect for


disconnection. disconnection.

A A
Go to A. Go to A.

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-42 4022-42

A A

Inspect for disconnection Inspect for disconnection

Cause and solution Cause and solution

Inspect whether there is conductance between the No YG802 harness defect Inspect whether there is conductance between the No YG802 harness defect
ground and terminal 2 of the CN.130 harness side. (disconnection) ground and terminal 2 of the CN.130 harness side. (disconnection)
Conductance Repair or replace Conductance Repair or replace

Yes Yes

Key switch ON Key switch ON

Cause and solution Cause and solution

No R253, GR250, R109, R106, or No R253, GR250, R109, R106, or


Measure the voltage between the ground and Measure the voltage between the ground and
R105 harness defect R105 harness defect
terminal 1 of the CN.130 harness side. terminal 1 of the CN.130 harness side.
(disconnection) (disconnection)
About 24 V About 24 V
Repair or replace Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-43 4022-43

Block diagram Block diagram


CONTROLLER A CONTROLLER A

“CAN COMMUNICATION” “CAN COMMUNICATION”

ENGINE ENGINE
CONTROLLER CONTROLLER

THROTTER VOL. THROTTER VOL.

PRESS. SENSOR (P1) PRESS. SENSOR (P1)

PRESS. SENSOR (P2) PRESS. SENSOR (P2)

PRESS. SENSOR PRESS. SENSOR


(PILOT UPPER) (PILOT UPPER)

PRESS. SENSOR PRESS. SENSOR


(PILOT TRAVEL) (PILOT TRAVEL)

BRAKER/CRUSHER BRAKER/CRUSHER
PILOT PRESS. PILOT PRESS.

2ND-OPTION LINE 2ND-OPTION LINE


PILOT PRESS. FUSE F5 PILOT PRESS. FUSE F5
(CONT) (CONT)

FUSE F3 ( KEY) FUSE F3 ( KEY)

KEY SWITCH KEY SWITCH

RELAY BATTERY RELAY BATTERY


BATTERY (24 V) BATTERY (24 V)

FUSIBLE LINK FUSIBLE LINK

BOX FUSE BOX FUSE

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-44 4022-44
DTC: 7203 DTC: 7203
Travel Alarm Buzzer Signal Abnormality Travel Alarm Buzzer Signal Abnormality

Travel alarm signal abnormality Travel alarm signal abnormality

Key switch ON Key switch ON


Diagnostic trouble code: 7203 ( ) is displayed •
Diagnostic trouble code: 7203 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Inspect the fusible link F1 (65A) fuse and fuse box F21 Inspect the fusible link F1 (65A) fuse and fuse box F21
(10A) fuse to see if either is blown. (10A) fuse to see if either is blown.

Inspect the travel alarm. Inspect the travel alarm.

Turn the key switch OFF and disconnect Turn the key switch OFF and disconnect
CN.149. CN.149.

Connect terminal 1 of the CN.149 travel alarm Cause and solution Connect terminal 1 of the CN.149 travel alarm Cause and solution
side to the negative terminal of the battery and No side to the negative terminal of the battery and No
Travel alarm defect Travel alarm defect
terminal 2 to the positive terminal, and inspect terminal 2 to the positive terminal, and inspect
Replacement Replacement
the operation of the travel alarm. the operation of the travel alarm.
Travel alarm sounds. Travel alarm sounds.

Yes Yes

DIAG MAIN 1 DTC1 7203 V DIAG MAIN 1 DTC1 7203 V

St/Oc •005 V DTC2 0238 V St/Oc •005 V DTC2 0238 V

1st 0010 V DTC3 ---- V 1st 0010 V DTC3 ---- V

Last 0901 V DTC4 ---- V Last 0901 V DTC4 ---- V

Inspect for shorts. Inspect for shorts.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
W840 harness defect (short) W840 harness defect (short)
terminal 2 of the CN.149 harness side. terminal 2 of the CN.149 harness side.
Replacement Replacement
0V 0V

Yes Yes

Key switch OFF Key switch OFF

Cause and solution Cause and solution

Inspect the conductance between the ground No GW225, R111, R106, or R105 Inspect the conductance between the ground No GW225, R111, R106, or R105
and terminal 1 of the CN.149 harness side. harness defect (short) and terminal 1 of the CN.149 harness side. harness defect (short)
No conductance Replacement No conductance Replacement

Yes Yes

A A
Go to A. Go to A.

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-45 4022-45

A A

Inspect for disconnection Inspect for disconnection

Cause and solution Cause and solution

Inspect whether there is conductance between the Inspect whether there is conductance between the
No W840 harness defect No W840 harness defect
ground and terminal 1 of the CN.149 harness side ground and terminal 1 of the CN.149 harness side
(disconnection) (disconnection)
for 0.4 sec. after the key switch is switched ON. for 0.4 sec. after the key switch is switched ON.
Repair or replace Repair or replace
Conductance Conductance

Yes Yes

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No GW225, R111, R106, or R105 Measure the voltage between the ground and No GW225, R111, R106, or R105
terminal 2 of the CN.149 harness side. harness defect (disconnection) terminal 2 of the CN.149 harness side. harness defect (disconnection)
About 24 V Repair or replace About 24 V Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram


PRESS. SENSOR PRESS. SENSOR
(PILOT TRAVEL) (PILOT TRAVEL)
FUSE F5 FUSE F5
(CONT) (CONT)

CONTROLLER A CONTROLLER A

FUSE F3 TRAVEL ALARM FUSE F3 TRAVEL ALARM


(KEY) (KEY)

KEY SWITCH KEY SWITCH

RELAY BATTERY RELAY BATTERY


BATTERY (24 V) BATTERY (24 V)

FUSIBLE LINK FUSIBLE LINK

BOX FUSE BOX FUSE

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-46 4022-46
DTC: 7209 DTC: 7209
Air Conditioner Coolant Temperature Signal Abnormality Air Conditioner Coolant Temperature Signal Abnormality

Air conditioner coolant temperature signal Air conditioner coolant temperature signal
abnormality abnormality

Key switch ON Key switch ON


Diagnostic trouble code: 7209 ( ) is displayed on •
Diagnostic trouble code: 7209 ( ) is displayed on
the service support DIAG screen. the service support DIAG screen.

Inspect the connection status of Inspect the connection status of


each connector. each connector.

Inspect for shorts. Inspect for shorts.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.28. disconnect CN.28.

Cause and solution Cause and solution


Inspect the conductance between terminals 11 No Inspect the conductance between terminals 11 No
OL822 harness defect (short) OL822 harness defect (short)
of the CN.28 harness side. of the CN.28 harness side.
Replacement Replacement
No conductance No conductance

Yes Yes

Inspect for Inspect for


disconnection disconnection

Key switch ON Key switch ON

Cause and solution Cause and solution


Measure the voltage between the ground and No OL822 harness defect Measure the voltage between the ground and No OL822 harness defect
terminal 11 of the CN.28 harness side. (disconnection) terminal 11 of the CN.28 harness side. (disconnection)

Yes Yes
Cause and solution Cause and solution
Computer A defect Computer A defect
Replacement Replacement

Block diagram Block diagram


ENGINE ENGINE
CONTROLLER WATER TEMP. SENSOTR CONTROLLER WATER TEMP. SENSOTR
CONTROLLER A CONTROLLER A

“CAN COMMUNICATION” “CAN COMMUNICATION”

AIR CONDITIONER AIR CONDITIONER

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-47 4022-47
DTC: 7210 DTC: 7210
Liftcrane Buzzer Signal Abnormality Liftcrane Buzzer Signal Abnormality

Liftcrane buzzer signal abnormality Liftcrane buzzer signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7210 displayed. Diagnostic trouble code: 7210 displayed.

Inspect the connection status of Inspect the connection status of


each connector. each connector.

Inspect the fusible link F1 (65A) fuse Inspect the fusible link F1 (65A) fuse
and fuse box F22 (15A) fuse to see and fuse box F22 (15A) fuse to see
if either is blown. if either is blown.

Inspect the liftcrane buzzer. Inspect the liftcrane buzzer.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.CR5, CN.CR6. disconnect CN.CR5, CN.CR6.

Connect the CN.CR6 liftcrane buzzer to the Cause and solution Connect the CN.CR6 liftcrane buzzer to the Cause and solution
negative terminal of the battery and the negative terminal of the battery and the
CN.CR5 liftcrane buzzer to the positive No Liftcrane buzzer defect CN.CR5 liftcrane buzzer to the positive No Liftcrane buzzer defect
terminal, and inspect the operation of the travel Replacement terminal, and inspect the operation of the travel Replacement
alarm. alarm.
Liftcrane buzzer sounds. Liftcrane buzzer sounds.

Yes Yes

Inspect for shorts. Inspect for shorts.

Key switch ON Key switch ON

Cause and solution Cause and solution

Measure the voltage between the ground and No Measure the voltage between the ground and No
W815 harness defect (short) W815 harness defect (short)
the CN.CR6 harness side. the CN.CR6 harness side.
Replacement Replacement
0V 0V

Yes Yes

Key switch OFF Key switch OFF

Cause and solution Cause and solution

Inspect the conductance between the ground No BrW237, BrW236, R111, R106 Inspect the conductance between the ground No BrW237, BrW236, R111, R106
and the CN.CR5 harness side. or R106 harness defect (short) and the CN.CR5 harness side. or R106 harness defect (short)
No conductance Replacement No conductance Replacement

Yes Yes

A A
Go to A. Go to A.

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-48 4022-48

A A

Inspect for disconnection Inspect for disconnection

Key switch ON Key switch ON

Cause and solution Cause and solution

BrW237, BrW236, R111, R106, BrW237, BrW236, R111, R106,


Measure the voltage between the ground and No Measure the voltage between the ground and No
or R105 harness defect or R105 harness defect
terminal CN.CR5 harness side. terminal CN.CR5 harness side.
(disconnection) (disconnection)
About 24 V About 24 V
Repair or replace Repair or replace

Yes Yes

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.CR4. disconnect CN.CR4.

Cause and solution Cause and solution

Inspect whether there is conductance between the Inspect whether there is conductance between the
No VG815 harness defect No VG815 harness defect
terminal 6 of the CN.CR4 harness side and the terminal 6 of the CN.CR4 harness side and the
(disconnection) (disconnection)
terminal CN.CR6 harness side. terminal CN.CR6 harness side.
Repair or replace Repair or replace
Conductance Conductance

Yes Yes

Cause and solution Cause and solution

Computer B defect Computer B defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-49 4022-49

Block diagram FUSE F5 Block diagram FUSE F5


(CONT) (CONT)

CONTROLLER A CONTROLLER A

“CAN COMMUNICATION” “CAN COMMUNICATION”


PRESS. SENSOR PRESS. SENSOR
BOOM BOTTOM BOOM BOTTOM

PRESS. SENSOR PRESS. SENSOR


BOOM ROD BOOM ROD

CONTROLLER B FUSE F3 CONTROLLER B FUSE F3


(KEY) (KEY)
BUZZER BUZZER

KEY SWITCH KEY SWITCH

RELAY BATTERY RELAY BATTERY


BATTERY (24 V) BATTERY (24 V)

FUSIBLE LINK FUSIBLE LINK

BOX FUSE BOX FUSE

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-50 4022-50
DTC: 7211 DTC: 7211
Rotating Light, Bucket Lock Signal Abnormality Rotating Light, Bucket Lock Signal Abnormality

Rotating light, bucket lock signal abnormality Rotating light, bucket lock signal abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7211 displayed. Diagnostic trouble code: 7211 displayed.

Inspect the connection status of Inspect the connection status of


each connector. each connector.

Inspect the fusible link F1 (65A) fuse Inspect the fusible link F1 (65A) fuse
and fuse box F21 (10A) fuse to see and fuse box F21 (10A) fuse to see
if either is blown. if either is blown.

Inspect the rotating light Inspect the rotating light

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.19. disconnect CN.19.

Cause and solution Cause and solution


Inspect the conductance between the terminal Inspect the conductance between the terminal
2 and terminal 1 of CN.C19 rotating light relay No Rotating light relay defect 2 and terminal 1 of CN.C19 rotating light relay No Rotating light relay defect
side. Replacement side. Replacement
Conductance Conductance

Yes Yes

Inspect for shorts. Inspect for shorts.

Connect CN.19. Connect CN.19.

Disconnect CN.CR4. Disconnect CN.CR4.

Cause and solution Cause and solution

No VW816, VW817, GW227, No VW816, VW817, GW227,


Inspect the conductance between the ground Inspect the conductance between the ground
GW226, GW225, R106 or GW226, GW225, R106 or
and the CN.CR4 harness side. and the CN.CR4 harness side.
R105 harness defect (short) R105 harness defect (short)
No conductance No conductance
Replacement Replacement

Yes Yes

Inspect for Inspect for


disconnection. disconnection.

A A
Go to A. Go to A.

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-51 4022-51

A A
Key switch ON Key switch ON

Cause and solution Cause and solution

VW816, VW817, GW227, VW816, VW817, GW227,


Measure the voltage between the ground and No GW226, GW225, R106 or R105 Measure the voltage between the ground and No GW226, GW225, R106 or R105
terminal 4 of CN.CR4 harness side. harness defect (disconnection) terminal 4 of CN.CR4 harness side. harness defect (disconnection)
Repair or replace Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer B defect Computer B defect


Replacement Replacement

Block diagram RELAY RIO Block diagram RELAY RIO


BEACON BEACON

SIGNAL LAMP SIGNAL LAMP

CONTROLLER B CONTROLLER B

CRANE MODE SWITCH CRANE MODE SWITCH

FUSE F5 FUSE F5
CONTROLLER A (CONT) CONTROLLER A (CONT)

“CAN COMMUNICATION” “CAN COMMUNICATION”

FUSE F3 (KEY) FUSE F3 (KEY)

KEY SWITCH KEY SWITCH

RELAY BATTERY RELAY BATTERY


BATTERY (24 V) BATTERY (24 V)

FUSIBLE LINK FUSIBLE LINK

BOX FUSE BOX FUSE

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-52 4022-52
DTC: 7240 DTC: 7240
Pump Horsepower Proportional Valve Signal Abnormality Pump Horsepower Proportional Valve Signal Abnormality

Pump horsepower proportional valve signal Pump horsepower proportional valve signal
abnormality abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7240 displayed. Diagnostic trouble code: 7240 displayed.

Inspect the connection status of Inspect the connection status of


each connector. each connector.

Reset the diagnostic trouble code on the Reset the diagnostic trouble code on the
service support DIAG screen. service support DIAG screen.

No No
Diagnostic trouble code: 7240 displayed. Diagnostic trouble code: 7240 displayed.

Yes Yes

A A
Go to A. Go to A.
Inspect for shorts. Inspect for shorts.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.113 disconnect CN.113

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground No
YR940 harness defect (short) YR940 harness defect (short)
and terminal 1 of the CN.113 harness side. and terminal 1 of the CN.113 harness side.
Replacement Replacement
No conductance No conductance

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-53 4022-53

A A

Inspect the pump Inspect the pump


horsepower proportional horsepower proportional
valve. valve.

Turn the key switch Turn the key switch


OFF and disconnect OFF and disconnect
CN.113. CN.113.

Cause and solution Cause and solution

Inspect the conductance between terminals 1 Inspect the conductance between terminals 1
No Pump horsepower proportional No Pump horsepower proportional
and 2 of the CN.113 pump horsepower and 2 of the CN.113 pump horsepower
valve defect valve defect
proportional valve side. proportional valve side.
Replacement Replacement
Conductance Conductance

Yes Yes

Inspect for disconnection. Inspect for disconnection.

Disconnect CN.B4. Disconnect CN.B4.

Cause and solution Cause and solution

Inspect the conductance between terminal 1 of YR940 harness defect Inspect the conductance between terminal 1 of YR940 harness defect
the CN.113 female side and terminal 17 of the No (disconnection) between CN.113 the CN.113 female side and terminal 17 of the No (disconnection) between CN.113
CN.B4 female side. and CN.B4 CN.B4 female side. and CN.B4
Conductance Repair or replace Conductance Repair or replace

Yes Yes

Cause and solution Cause and solution

Inspect the conductance between terminal 2 of BY941 harness defect Inspect the conductance between terminal 2 of BY941 harness defect
the CN.113 female side and terminal 18 of the No (disconnection) between CN.113 the CN.113 female side and terminal 18 of the No (disconnection) between CN.113
CN.B4 female side. and CN.B4 CN.B4 female side. and CN.B4
Conductance Repair or replace Conductance Repair or replace

Yes Yes

Disconnect CN.C3. Disconnect CN.C3.

B B
Go to B. Go to B.

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-54 4022-54

B B
Cause and solution Cause and solution

Inspect the conductance between terminal 17 of YR940 harness defect Inspect the conductance between terminal 17 of YR940 harness defect
the CN.B4 male side and terminal 3 of the CN.C3 No (disconnection) between CN.B4 the CN.B4 male side and terminal 3 of the CN.C3 No (disconnection) between CN.B4
female side. and CN.C3 female side. and CN.C3
Conductance Repair or replace Conductance Repair or replace

Yes Yes

Cause and solution Cause and solution

Inspect the conductance between terminal 18 of BY941 harness defect Inspect the conductance between terminal 18 of BY941 harness defect
the CN.B4 male side and erminal 6 of the CN.C3 No (disconnection) between CN.B4 the CN.B4 male side and erminal 6 of the CN.C3 No (disconnection) between CN.B4
female side. and CN.C3 female side. and CN.C3
Conductance Repair or replace Conductance Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram


CONTROLLER A CONTROLLER A
PRESS. SENSOR (P1) PRESS. SENSOR (P1)

PRESS. SENSOR (P2) PRESS. SENSOR (P2)

PRESS. SENSOR PRESS. SENSOR


(PILOT UPPER) (PILOT UPPER)

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

“CAN COMMUNICATION” “CAN COMMUNICATION”


ENGINE ENGINE
CONTROLLER CONTROLLER

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-55 4022-55
DTC: 7241 DTC: 7241
P1 Flow Control Proportional Valve Signal Abnormality P1 Flow Control Proportional Valve Signal Abnormality

P1 flow control proportional valve signal P1 flow control proportional valve signal
abnormality abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7241 displayed. Diagnostic trouble code: 7241 displayed.

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Reset the diagnostic trouble code on the Reset the diagnostic trouble code on the
service support DIAG screen. service support DIAG screen.

DIAG MAIN 1 DTC1 7241 V DIAG MAIN 1 DTC1 7241 V

St/Oc •005 V DTC2 0238 V St/Oc •005 V DTC2 0238 V

1st 0010 V DTC3 ---- V 1st 0010 V DTC3 ---- V

Last 0901 V DTC4 ---- V Last 0901 V DTC4 ---- V

No No
Diagnostic trouble code: 7241 displayed. Diagnostic trouble code: 7241 displayed.

Yes Yes

A A
Go to A. Go to A.

Inspect for shorts. Inspect for shorts.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.114. disconnect CN.114.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground No
LR942 harness defect (short) LR942 harness defect (short)
and terminal 1 of the CN.114 harness side. and terminal 1 of the CN.114 harness side.
Replacement Replacement
No conductance No conductance

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-56 4022-56

A A

Inspect the P1 flow control Inspect the P1 flow control


proportional valve. proportional valve.

Turn the key switch Turn the key switch


OFF and disconnect OFF and disconnect
CN.114. CN.114.

Cause and solution Cause and solution

Inspect the conductance between terminals 1 Inspect the conductance between terminals 1
No P1 flow control proportional No P1 flow control proportional
and 2 of the CN.114 P1 flow control proportional and 2 of the CN.114 P1 flow control proportional
valve defect valve defect
valve side. valve side.
Replacement Replacement
Conductance Conductance

Yes Yes

Inspect for disconnection. Inspect for disconnection.

Disconnect CN.B4. Disconnect CN.B4.

Cause and solution Cause and solution

Inspect the conductance between terminal 1 of LR942 harness defect Inspect the conductance between terminal 1 of LR942 harness defect
the CN.114 female side and terminal 19 of the No (disconnection) between CN.114 the CN.114 female side and terminal 19 of the No (disconnection) between CN.114
CN.B4 female side. and CN.B4 CN.B4 female side. and CN.B4
Conductance Repair or replace Conductance Repair or replace

Yes Yes

Cause and solution Cause and solution

Inspect the conductance between terminal 2 of BL943 harness defect Inspect the conductance between terminal 2 of BL943 harness defect
the CN.114 female side and terminal 20 of the No (disconnection) between CN.114 the CN.114 female side and terminal 20 of the No (disconnection) between CN.114
CN.B4 female side. and CN.B4 CN.B4 female side. and CN.B4
Conductance Repair or replace Conductance Repair or replace

Yes Yes

Disconnect CN.C3. Disconnect CN.C3.

B B
Go to B. Go to B.

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-57 4022-57

B B
Cause and solution Cause and solution

Inspect the conductance between terminal 19 of LR942 harness defect Inspect the conductance between terminal 19 of LR942 harness defect
the CN.B4 male side and terminal 2 of the CN.C3 No (disconnection) between CN.B4 the CN.B4 male side and terminal 2 of the CN.C3 No (disconnection) between CN.B4
female side. and CN.C3 female side. and CN.C3
Conductance Repair or replace Conductance Repair or replace

Cause and solution Cause and solution

Inspect the conductance between terminal 20 of BL943 harness defect Inspect the conductance between terminal 20 of BL943 harness defect
the CN.B4 male side and erminal 5 of the CN.C3 No (disconnection) between CN.B4 the CN.B4 male side and erminal 5 of the CN.C3 No (disconnection) between CN.B4
female side. and CN.C3 female side. and CN.C3
Conductance Repair or replace Conductance Repair or replace

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram


PRESS. SENSOR PRESS. SENSOR
CONTROLLER A (PILOT SWING) CONTROLLER A (PILOT SWING)

PRESS. SENSOR PRESS. SENSOR


(PILOT UPPER) (PILOT UPPER)

PRESS. SENSOR PRESS. SENSOR


(PILOT TRAVEL) (PILOT TRAVEL)

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

“CAN COMMUNICATION” “CAN COMMUNICATION”


ENGINE ENGINE
CONTROLLER CONTROLLER

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-58 4022-58
DTC: DTC:
7400 Abnormally High Coolant Temperature (105 or higher) 7400 Abnormally High Coolant Temperature (105 or higher)
7402 Abnormally High Coolant Temperature (110 °C or higher) 7402 Abnormally High Coolant Temperature (110 °C or higher)
7403 Abnormally High Coolant Temperature (120 °C or higher) 7403 Abnormally High Coolant Temperature (120 °C or higher)

Abnormally high Abnormally high


water temperature water temperature

Engine start complete Engine start complete


warm-up warm-up


Diagnostic trouble code: 7400 ( ) is displayed •
Diagnostic trouble code: 7400 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.

Cause and solution Cause and solution

Inspect the engine unit. Inspect the engine unit.

Block diagram Block diagram


ENGINE ENGINE
CONTROLLER WATER TEMP. SENSOR CONTROLLER WATER TEMP. SENSOR
CONTROLLER A CONTROLLER A

“CAN COMMUNICATION” “CAN COMMUNICATION”

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-59 4022-59
DTC: 7404 DTC: 7404
Abnormally High Oil Temperature (95 °C or higher) Abnormally High Oil Temperature (95 °C or higher)

Abnormally high oil Abnormally high oil


temperature temperature

Engine start complete Engine start complete


warm-up warm-up


Diagnostic trouble code: 7404 ( ) is displayed •
Diagnostic trouble code: 7404 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.

Cause and solution Cause and solution

Inspect the hydraulic oil temperature. Inspect the hydraulic oil temperature.

Block diagram Block diagram

CONTROLLER A CONTROLLER A

HYD. OIL TEMP. SENSOR HYD. OIL TEMP. SENSOR

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-60 4022-60
DTC: DTC:
7405 Abnormally High Boost Temperature (80 °C or higher) 7405 Abnormally High Boost Temperature (80 °C or higher)
7406 Abnormally High Boost Temperature (90 °C or higher) 7406 Abnormally High Boost Temperature (90 °C or higher)

Abnormally high Abnormally high


water temperature water temperature

Engine start complete Engine start complete


warm-up warm-up


Diagnostic trouble code: 7405 ( ) is displayed •
Diagnostic trouble code: 7405 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.

Cause and solution Cause and solution

Inspect the engine unit. Inspect the engine unit.

Block diagram ENGINE


Block diagram ENGINE
CONTROLLER BOOST TEMP. SENSOR CONTROLLER BOOST TEMP. SENSOR
CONTROLLER A CONTROLLER A

“CAN COMMUNICATION” “CAN COMMUNICATION”

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-61 4022-61
DTC: 7420 DTC: 7420
Abnormally Low Alternator Voltage Abnormally Low Alternator Voltage

Alternator voltage abnormality Alternator voltage abnormality

Key switch ON Key switch ON


Diagnostic trouble code: 7420 ( ) is displayed •
Diagnostic trouble code: 7420 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.

Inspect the connection status of Inspect the connection status of


each connector. each connector.

Inspect for shorts. Inspect for shorts.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.110. disconnect CN.110.

Cause and solution Cause and solution

Inspect the conductance between the ground No Br016 or BrR523 harness Inspect the conductance between the ground No Br016 or BrR523 harness
and terminal 2 of the CN.110 harness side. defect (short) and terminal 2 of the CN.110 harness side. defect (short)
No conductance Replacement No conductance Replacement

Yes Yes

Inspect the Inspect the


alternator. alternator.

Engine start Engine start

Cause and solution Cause and solution

Measure the voltage between the ground and Yes Measure the voltage between the ground and Yes
Alternator defect Alternator defect
terminal 2 of the CN.110 alternator side. terminal 2 of the CN.110 alternator side.
Replacement Replacement
10 V or lower 10 V or lower

No No

A A
Go to A. Go to A.

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-62 4022-62

A A

Inspect for disconnection. Inspect for disconnection.

Turn the key switch OFF and connect Turn the key switch OFF and connect
CN.110. CN.110.

Disconnect CN.C1 and start the Disconnect CN.C1 and start the
engine. engine.

Cause and solution Cause and solution

Measure the voltage between the ground and Br016 or BrR523 harness defect Measure the voltage between the ground and Br016 or BrR523 harness defect
terminal 8 of the CN.C1 harness side. Yes (disconnection) terminal 8 of the CN.C1 harness side. Yes (disconnection)
10 V or lower Repair or replace 10 V or lower Repair or replace

No No

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram FUSE F5 FUSE F3


Block diagram FUSE F5 FUSE F3
CONTROLLER A (CONT) (KEY) CONTROLLER A (CONT) (KEY)

KEY SWITCH KEY SWITCH

RELAY R11 FUSIBLE LINK FUSIBLE LINK RELAY R11 FUSIBLE LINK FUSIBLE LINK
STARTER CUT STARTER CUT

BATTERY RELAY BATTERY BATTERY RELAY BATTERY


(24 V) STARTER MOTOR (24 V) STARTER MOTOR

ALTERNATOR ALTERNATOR

RELAY SAFETY RELAY SAFETY

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-63 4022-63
DTC: 7421 DTC: 7421
Coolant Level Reduction Coolant Level Reduction

"LOW COOLANT" display appears. "LOW COOLANT" display appears.

Refill coolant Refill coolant

Key switch ON Key switch ON


Diagnostic trouble code: 7421 ( ) is displayed •
Diagnostic trouble code: 7421 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.

DIAG MAIN 1 DTC1 7241 V DIAG MAIN 1 DTC1 7241 V

St/Oc •005 V DTC2 0238 V St/Oc •005 V DTC2 0238 V

1st 0010 V DTC3 ---- V 1st 0010 V DTC3 ---- V

Last 0901 V DTC4 ---- V Last 0901 V DTC4 ---- V

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Inspect the coolant level switch. Inspect the coolant level switch.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.138. disconnect CN.138.

Cause and solution Cause and solution

Inspect the conductance between terminals 1 No Inspect the conductance between terminals 1 No
Coolant level switch defect Coolant level switch defect
and 2 of the CN.138 coolant level switch side. and 2 of the CN.138 coolant level switch side.
Replacement Replacement
No conductance No conductance

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A CONTROLLER A

LIMIT SWITCH LIMIT SWITCH


(RESERVE TANK) (RESERVE TANK)

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-64 4022-64
DTC: 7422 DTC: 7422
Abnormally Low Engine Oil Pressure Abnormally Low Engine Oil Pressure

Abnormally low Abnormally low


engine oil pressure engine oil pressure

30 sec. standby engine 30 sec. standby engine


start start


Diagnostic trouble code: 7422 ( ) is displayed •
Diagnostic trouble code: 7422 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.

Cause and solution Cause and solution

Inspect the engine unit. Inspect the engine unit.

Block diagram Block diagram


ENGINE ENGINE
CONTROLLER CONTROLLER
CONTROLLER A OIL PRESS. SENSOR CONTROLLER A OIL PRESS. SENSOR

“CAN COMMUNICATION” “CAN COMMUNICATION”

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-65 4022-65
DTC: 7423 DTC: 7423
Air Cleaner Clogging Air Cleaner Clogging

"AIR FILTER" display appears. "AIR FILTER" display appears.

Clean or replace the air cleaner Clean or replace the air cleaner
element. element.

10 sec. standby engine 10 sec. standby engine


start start


Diagnostic trouble code: 7423 ( ) is displayed •
Diagnostic trouble code: 7423 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.

DIAG MAIN 1 DTC1 7423 V DIAG MAIN 1 DTC1 7423 V

St/Oc •005 V DTC2 0238 V St/Oc •005 V DTC2 0238 V

1st 0010 V DTC3 ---- V 1st 0010 V DTC3 ---- V

Last 0901 V DTC4 ---- V Last 0901 V DTC4 ---- V

Inspect the connection status of each Inspect the connection status of each
connector. connector.

Inspect the air cleaner clog pressure switch. Inspect the air cleaner clog pressure switch.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.139. disconnect CN.139.

Cause and solution Cause and solution

Inspect the conductance between terminals 1 No Inspect the conductance between terminals 1 No
Air cleaner clog pressure Air cleaner clog pressure
and 2 of the CN.139 air cleaner clog pressure and 2 of the CN.139 air cleaner clog pressure
switch defect switch defect
switch side. switch side.
Replacement Replacement
No conductance No conductance

Yes Yes

Inspect for shorts. Inspect for shorts.

Cause and solution Cause and solution

Inspect the conductance between the ground No Inspect the conductance between the ground No
LM471 harness defect (short) LM471 harness defect (short)
and terminal 2 of the CN.139 harness side. and terminal 2 of the CN.139 harness side.
Replacement Replacement
No conductance No conductance

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-66 4022-66

Block diagram Block diagram


CONTROLLER A CONTROLLER A

PRESS. SWITCH PRESS. SWITCH


(AIR CLEANNER) (AIR CLEANNER)

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-67 4022-67
DTC: 7424 DTC: 7424
Return Filter Clogging (breaker specifications) Return Filter Clogging (breaker specifications)

"CHECK HYD. OIL FILTER" display appears. "CHECK HYD. OIL FILTER" display appears.

Return filter replacement Return filter replacement

Key switch ON Key switch ON

Diagnostic trouble code: 7424 displayed. Diagnostic trouble code: 7424 displayed.

Inspect the connection status of each Inspect the connection status of each
connector and ground. connector and ground.

Inspect the return filter clog switch. Inspect the return filter clog switch.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.134. disconnect CN.134.

Cause and solution Cause and solution

Inspect the conductance between terminals 1 No Return filter clog switch Inspect the conductance between terminals 1 No Return filter clog switch
and 2 of the CN.134 return filter clog switch side. defect and 2 of the CN.134 return filter clog switch side. defect
Conductance Replacement Conductance Replacement

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram


CONTROLLER A CONTROLLER A

PRESS. SWITCH PRESS. SWITCH


(FILTER INDICATOR) (FILTER INDICATOR)

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-68 4022-68
DTC: 7600 DTC: 7600
CAN Bus Abnormality CAN Bus Abnormality

CAN bus CAN bus


abnormality abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7600 displayed. Diagnostic trouble code: 7600 displayed.

Inspect the connection status of Inspect the connection status of


each connector. each connector.

Inspect for shorts. Inspect for shorts.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.50. Cause and solution disconnect CN.50. Cause and solution

Inspect the conductance between the ground No P040, P042, P044, or P048 Inspect the conductance between the ground No P040, P042, P044, or P048
and terminal A of the CN.50 harness side. arness defect (short) and terminal A of the CN.50 harness side. arness defect (short)
No conductance Replacement No conductance Replacement

Yes Yes

Cause and solution Cause and solution

Inspect the conductance between the ground No PG041, PG043, PG045, or Inspect the conductance between the ground No PG041, PG043, PG045, or
and terminal B of the CN.50 harness side. P049 harness defect (short) and terminal B of the CN.50 harness side. P049 harness defect (short)
No conductance Replacement No conductance Replacement

Yes Yes

Cause and solution Cause and solution

Inspect the conductance between terminals A No P040, P042, P044, P048, PG041, PG043, Inspect the conductance between terminals A No P040, P042, P044, P048, PG041, PG043,
and B of the CN.50 harness side. PG045, or P049 harness defect (short) and B of the CN.50 harness side. PG045, or P049 harness defect (short)
No conductance Replacement No conductance Replacement

Yes Yes
Connect CN.50. Connect CN.50.

Inspect the ECM, Computer A, Computer B, Inspect the ECM, Computer A, Computer B,
and Computer S units. and Computer S units.

Disconnect CN.A0 and Disconnect CN.A0 and


turn the key switch ON. Cause and solution turn the key switch ON. Cause and solution

Is diagnostic trouble code: 7600 displayed? No ECM defect Is diagnostic trouble code: 7600 displayed? No ECM defect
Displayed Replacement Displayed Replacement

Yes Yes

A A
Go to A. Go to A.

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-69 4022-69

A A
Turn the key switch OFF and Turn the key switch OFF and
connect CN.A0. connect CN.A0.

Disconnect CN.C2 and turn Disconnect CN.C2 and turn


the key switch ON. the key switch ON.

Cause and solution Cause and solution

Is diagnostic trouble code: 7600 displayed? No Computer A defect Is diagnostic trouble code: 7600 displayed? No Computer A defect
Displayed Replacement Displayed Replacement

Yes Yes

Turn the key switch OFF and Turn the key switch OFF and
connect CN.C2. connect CN.C2.

Disconnect CN.CR2 and turn Disconnect CN.CR2 and turn


the key switch ON. the key switch ON.

Cause and solution Cause and solution

Is diagnostic trouble code: 7600 displayed? No Computer B defect Is diagnostic trouble code: 7600 displayed? No Computer B defect
Displayed Replacement Displayed Replacement

Yes Yes

Cause and solution Cause and solution

Computer S defect Computer S defect


Replacement Replacement

Block diagram Block diagram


“CAN COMMUNICATION” CONTROLLER A “CAN COMMUNICATION” CONTROLLER A
DEUTSCH DEUTSCH

CONTROLLER S CONTROLLER B ENGINE CONTROLLER CONTROLLER S CONTROLLER B ENGINE CONTROLLER

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-70 4022-70
DTC: 7601 DTC: 7601
Monitor Communication Abnormality Monitor Communication Abnormality

Monitor Monitor
communication communication
abnormality abnormality

Key switch ON Key switch ON

Diagnostic trouble code: 7601 displayed. Diagnostic trouble code: 7601 displayed.

Inspect the connection status of Inspect the connection status of


each connector. each connector.

Inspect for Inspect for


disconnection. disconnection.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.C2 and CN.C5. Cause and solution disconnect CN.C2 and CN.C5. Cause and solution

Inspect the conductance between terminal 12 No Inspect the conductance between terminal 12 No
PL056 harness defect PL056 harness defect
of the CN.C2 harness side and terminal 4 of of the CN.C2 harness side and terminal 4 of
(disconnection) (disconnection)
the CN.C5 harness side. the CN.C5 harness side.
Repair or replace Repair or replace
Conductance Conductance

Yes Yes

Cause and solution Cause and solution

Inspect the conductance between terminal 4 of No Inspect the conductance between terminal 4 of No
PW055 harness defect PW055 harness defect
the CN.C2 harness side and terminal 13 of the the CN.C2 harness side and terminal 13 of the
(disconnection) (disconnection)
CN.C5 harness side. CN.C5 harness side.
Repair or replace Repair or replace
Conductance Conductance

Yes Yes
Turn the key switch ON. Turn the key switch ON.
Cause and solution Cause and solution

Is diagnostic trouble code: 7601 displayed? No Monitor defect Is diagnostic trouble code: 7601 displayed? No Monitor defect
Displayed Replacement Displayed Replacement

Yes Yes

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A MONITOR CONTROLLER A MONITOR

“SERIAL COMMUNICATION” “SERIAL COMMUNICATION”

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-71 4022-71
DTC: 7602 DTC: 7602
ECM Communication Abnormality ECM Communication Abnormality

ECM communication time-out ECM communication time-out

Key switch ON Key switch ON

Diagnostic trouble code: 7602 displayed. Diagnostic trouble code: 7602 displayed.

Inspect the connection status of Inspect the connection status of


each connector. Cause and solution each connector. Cause and solution

Are diagnostic trouble codes 7603 and 7604 Yes Are diagnostic trouble codes 7603 and 7604 Yes
Inspect the connection status of Inspect the connection status of
displayed at the same time? displayed at the same time?
CN.C2. CN.C2.
Displayed Displayed

No No

Inspect for Inspect for


disconnection. disconnection.

Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.C2 and CN.A0. Cause and solution disconnect CN.C2 and CN.A0. Cause and solution

Inspect the conductance between terminal 6 of No Inspect the conductance between terminal 6 of No
P040 or P042 harness defect P040 or P042 harness defect
the CN.C2 harness side and terminal 18 of the the CN.C2 harness side and terminal 18 of the
(disconnection) (disconnection)
CN.A0 harness side. CN.A0 harness side.
Repair or replace Repair or replace
Conductance Conductance

Yes Yes

Cause and solution Cause and solution

Inspect the conductance between terminal 14 No Inspect the conductance between terminal 14 No
PG041 or PG043 harness PG041 or PG043 harness
of the CN.C2 harness side and terminal 37 of of the CN.C2 harness side and terminal 37 of
defect (disconnection) defect (disconnection)
the CN.A0 harness side. the CN.A0 harness side.
Repair or replace Repair or replace
Conductance Conductance

Yes Yes

Cause and solution Cause and solution

ECM defect ECM defect


Replacement Replacement

Block diagram Block diagram


“CAN COMMUNICATION” CONTROLLER A “CAN COMMUNICATION” CONTROLLER A
DEUTSCH DEUTSCH

CONTROLLER S CONTROLLER B ENGINE CONTROLLER CONTROLLER S CONTROLLER B ENGINE CONTROLLER

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-72 4022-72
DTC: 7605 DTC: 7605
ECM Mismatch ECM Mismatch

ECM mismatch ECM mismatch

Key switch ON Key switch ON

Diagnostic trouble code: 7605 displayed. Diagnostic trouble code: 7605 displayed.

Cause and solution Cause and solution

Is there an error on the service support model No Is there an error on the service support model No
Correctly set the model Correctly set the model
selection screen? selection screen?
selection. selection.
Correct Correct

Yes Yes

Cause and solution Cause and solution

Is the ECM which matches the model No Is the ECM which matches the model No
Replace with an ECM that Replace with an ECM that
installed? installed?
matches the model. matches the model.
Supported Supported

Yes Yes

Cause and solution Cause and solution

ECM defect ECM defect


Replacement Replacement

Block diagram Block diagram

CONTROLLER A CONTROLLER A

ENGINE ENGINE
CONTROLLER CONTROLLER

“CAN COMMUNICATION” “CAN COMMUNICATION”

Lep NST-10-07-001-0EN Issued 10-08 Lep NST-10-07-001-0EN Issued 10-08


4022-73 4022-73
DTC: 7606 DTC: 7606
EEPROM Data Abnormality EEPROM Data Abnormality

EEPROM data EEPROM data


abnormality abnormality

Key switch ON Key switch ON


Diagnostic trouble code: 7606 ( ) is displayed •
Diagnostic trouble code: 7606 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.

Cause and solution Cause and solution

Yes Rewriting of the computer changed the used space Yes Rewriting of the computer changed the used space
Was rewriting performed on computer A before Was rewriting performed on computer A before
of the EEPROM. of the EEPROM.
the diagnostic trouble code was displayed? the diagnostic trouble code was displayed?
Turn the key switch OFF and then turn it ON again. Turn the key switch OFF and then turn it ON again.

No No

Cause and solution Cause and solution

Computer A defect Computer A defect


Replacement Replacement

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NOTES NOTES

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Section Section

4023

4023
4023 4023

TROUBLESHOOTING TROUBLESHOOTING
4JJ1 ENGINE 4JJ1 ENGINE

Copyright © 2008 CNH France S.A. Copyright © 2008 CNH France S.A.
Printed in France Printed in France
CNH Lep SM130B4023-0EN October 2008 CNH Lep SM130B4023-0EN October 2008
4023-2 4023-2
TABLE OF CONTENTS TABLE OF CONTENTS
Special tools ........................................................................................................................................................... 4 Special tools ........................................................................................................................................................... 4
Reading Flow Charts ............................................................................................................................................. 5 Reading Flow Charts ............................................................................................................................................. 5
Diagnostic Trouble Code Number and Problem ................................................................................................. 5 Diagnostic Trouble Code Number and Problem ................................................................................................. 5
Abbreviation Table .............................................................................................................................................. 6 Abbreviation Table .............................................................................................................................................. 6
About Wiring Colors ............................................................................................................................................ 7 About Wiring Colors ............................................................................................................................................ 7
Reading Block Diagrams..................................................................................................................................... 8 Reading Block Diagrams..................................................................................................................................... 8
Reading Trouble Diagnosis............................................................................................................................... 10 Reading Trouble Diagnosis............................................................................................................................... 10
Cautions for Maintenance ................................................................................................................................... 16 Cautions for Maintenance ................................................................................................................................... 16
Electrical System............................................................................................................................................... 16 Electrical System............................................................................................................................................... 16
Fuel Injection System........................................................................................................................................ 16 Fuel Injection System........................................................................................................................................ 16
How to Proceed with Trouble Diagnosis ........................................................................................................... 17 How to Proceed with Trouble Diagnosis ........................................................................................................... 17
Trouble Diagnosis Procedure............................................................................................................................ 17 Trouble Diagnosis Procedure............................................................................................................................ 17
Inquiry ............................................................................................................................................................... 18 Inquiry ............................................................................................................................................................... 18
Preliminary Inspection....................................................................................................................................... 20 Preliminary Inspection....................................................................................................................................... 20
Trouble with related systems ............................................................................................................................ 20 Trouble with related systems ............................................................................................................................ 20
Trouble Diagnosis ............................................................................................................................................. 20 Trouble Diagnosis ............................................................................................................................................. 20
Diagnostic Trouble Code Reading Procedure................................................................................................... 22 Diagnostic Trouble Code Reading Procedure................................................................................................... 22
Confirmation after Repair .................................................................................................................................. 23 Confirmation after Repair .................................................................................................................................. 23
Final Confirmation Items List............................................................................................................................. 23 Final Confirmation Items List............................................................................................................................. 23
Diagnostic Trouble Code Deletion Method ....................................................................................................... 23 Diagnostic Trouble Code Deletion Method ....................................................................................................... 23
Injector Inspection Methods Using A Thermogun ............................................................................................. 24 Injector Inspection Methods Using A Thermogun ............................................................................................. 24
Sorting Methods Using Noncontact Infrared Thermometer............................................................................... 31 Sorting Methods Using Noncontact Infrared Thermometer............................................................................... 31
Breaker Box Inspection Procedure ................................................................................................................... 32 Breaker Box Inspection Procedure ................................................................................................................... 32
Engine Control System........................................................................................................................................ 35 Engine Control System........................................................................................................................................ 35
Engine Control (common rail) System Functions and Operation Explanation .................................................. 35 Engine Control (common rail) System Functions and Operation Explanation .................................................. 35
Engine Control Module (ECM) .......................................................................................................................... 43 Engine Control Module (ECM) .......................................................................................................................... 43
Engine Component Parts Layout Diagram........................................................................................................ 45 Engine Component Parts Layout Diagram........................................................................................................ 45
Engine Control Module (ECM) Wiring Diagram ................................................................................................ 63 Engine Control Module (ECM) Wiring Diagram ................................................................................................ 63
Engine Control Module (ECM) Pin Layout ........................................................................................................ 64 Engine Control Module (ECM) Pin Layout ........................................................................................................ 64
Circuit Diagram ................................................................................................................................................. 68 Circuit Diagram ................................................................................................................................................. 68
Engine Harness Routing Diagram..................................................................................................................... 78 Engine Harness Routing Diagram..................................................................................................................... 78
Connector List ................................................................................................................................................... 82 Connector List ................................................................................................................................................... 82
Function Inspection List...................................................................................................................................... 84 Function Inspection List...................................................................................................................................... 84
Function Inspection List .................................................................................................................................... 84 Function Inspection List .................................................................................................................................... 84
Checking the Start Circuit System .................................................................................................................... 86 Checking the Start Circuit System .................................................................................................................... 86
Checking the Start System................................................................................................................................ 90 Checking the Start System................................................................................................................................ 90
Checking the start system................................................................................................................................. 90 Checking the start system................................................................................................................................. 90
Checking the Fuel System ................................................................................................................................ 92 Checking the Fuel System ................................................................................................................................ 92
Checking the Suction Air System...................................................................................................................... 96 Checking the Suction Air System...................................................................................................................... 96
Checking the Exhaust System .......................................................................................................................... 96 Checking the Exhaust System .......................................................................................................................... 96
Exhaust system................................................................................................................................................. 96 Exhaust system................................................................................................................................................. 96
Checking the EGR Control System................................................................................................................... 97 Checking the EGR Control System................................................................................................................... 97
Problem Symptom List ........................................................................................................................................ 99 Problem Symptom List ........................................................................................................................................ 99
Problem Symptom List ...................................................................................................................................... 99 Problem Symptom List ...................................................................................................................................... 99
Engine Start Problem ...................................................................................................................................... 100 Engine Start Problem ...................................................................................................................................... 100
Engine Stalling ................................................................................................................................................ 104 Engine Stalling ................................................................................................................................................ 104
Engine Hunting, Unstable Idling Speed .......................................................................................................... 108 Engine Hunting, Unstable Idling Speed .......................................................................................................... 108
Engine Output Deficiency................................................................................................................................ 112 Engine Output Deficiency................................................................................................................................ 112
Excessive White Smoke in Exhaust Gas ........................................................................................................ 116 Excessive White Smoke in Exhaust Gas ........................................................................................................ 116
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Excessive Black Smoke in Exhaust Gas......................................................................................................... 118 Excessive Black Smoke in Exhaust Gas......................................................................................................... 118
Abnormal Noise............................................................................................................................................... 120 Abnormal Noise............................................................................................................................................... 120
High Fuel Consumption................................................................................................................................... 122 High Fuel Consumption................................................................................................................................... 122
High Oil Consumption ..................................................................................................................................... 125 High Oil Consumption ..................................................................................................................................... 125
Tech 2 Data Reference Values .......................................................................................................................... 127 Tech 2 Data Reference Values .......................................................................................................................... 127

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SPECIAL TOOLS SPECIAL TOOLS

Tool No. Tool No.


Illustration Illustration
Tool name Tool name

Digital multi meter Digital multi meter

Terminal remover Terminal remover

Weather pack terminal Weather pack terminal


remover remover

Thermo gun Thermo gun

Breaker box Breaker box


380002653 380002653

5884003850 5884003850

EST (Electronic Service tools) EST (Electronic Service tools)

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Reading Flow Charts Reading Flow Charts


Diagnostic Trouble Code Number and Problem Diagnostic Trouble Code Number and Problem
The diagnostic trouble code number and problem are listed above the flow chart. The diagnostic trouble code number and problem are listed above the flow chart.
How to proceed How to proceed
• Continue with either the YES or NO branch for the inspection and measurement result in and go to the next • Continue with either the YES or NO branch for the inspection and measurement result in and go to the next
. .

• contains inspection and measurement methods and values.If there is agreement with the values and question in • contains inspection and measurement methods and values.If there is agreement with the values and question in
, then the result is YES. The result is NO if there is no agreement. , then the result is YES. The result is NO if there is no agreement.

Electrical wiring colors Electrical wiring colors


See the table below for electrical wiring colors in measurement locations when doing troubleshooting. See the table below for electrical wiring colors in measurement locations when doing troubleshooting.
Electrical wiring color distinctions Electrical wiring color distinctions
Symbol B W Br P V G O Symbol B W Br P V G O
Color Black White Brown Pink Violet Green Orange Color Black White Brown Pink Violet Green Orange
Symbol R Y Lg Sb L Gr Symbol R Y Lg Sb L Gr
Color Red Yellow Light green Sky blue Blue Gray Color Red Yellow Light green Sky blue Blue Gray

"ab" indicates there is a color "b" stripe on the electrical wire color "a" base. "ab" indicates there is a color "b" stripe on the electrical wire color "a" base.
Ex.) BR: Red stripe on black base color. Ex.) BR: Red stripe on black base color.

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4023-6 4023-6
Abbreviation Table Abbreviation Table
Abbreviation Name Meaning, remarks Abbreviation Name Meaning, remarks
Communication technique used for communication between ECM and Communication technique used for communication between ECM and
CAN Controller area network CAN Controller area network
computer A computer A
A sensor that detects the angle of rotation of the crankshaft A sensor that detects the angle of rotation of the crankshaft
CKP sensor Crankshaft position sensor CKP sensor Crankshaft position sensor
It is installed on the flywheel housing. It is installed on the flywheel housing.
A sensor that detects the angle of rotation of the camshaft A sensor that detects the angle of rotation of the camshaft
CMP sensor Camshaft position sensor CMP sensor Camshaft position sensor
It is installed on the rear of the cylinder head. It is installed on the rear of the cylinder head.
DMM Digital multi-meter Tester for diagnosing electrical systems DMM Digital multi-meter Tester for diagnosing electrical systems
This is a self-diagnosis code. There is a code number for each trouble This is a self-diagnosis code. There is a code number for each trouble
DTC Diagnostic trouble code DTC Diagnostic trouble code
location. location.
ECM Engine control module A computer for engine control and this is the core of engine control. ECM Engine control module A computer for engine control and this is the core of engine control.
ECT sensor Engine coolant temperature sensor Engine coolant temperature sensor ECT sensor Engine coolant temperature sensor Engine coolant temperature sensor
ECU Electronic control unit Microcomputer for various control functions ECU Electronic control unit Microcomputer for various control functions
Exhaust gas recirculation recirculates part of the exhaust gas from the Exhaust gas recirculation recirculates part of the exhaust gas from the
engine into the intake system, this mixes with new mixed air to reduce engine into the intake system, this mixes with new mixed air to reduce
EGR Exhaust gas recirculation EGR Exhaust gas recirculation
the combustion temperature, which suppresses the generation of the combustion temperature, which suppresses the generation of
nitrogen oxides (NOx). nitrogen oxides (NOx).
EMPS Engine module programming system System for rewriting ECM control programs EMPS Engine module programming system System for rewriting ECM control programs
Fuel temperature sensor Fuel temperature sensor
FT sensor Fuel temperature sensor FT sensor Fuel temperature sensor
Installed on the supply pump. Installed on the supply pump.
GND Ground Ground GND Ground Ground
IAT sensor Inlet air temperature sensor Suction air temperature sensor IAT sensor Inlet air temperature sensor Suction air temperature sensor
Valve that controls the flow of fuel to the common rail. Valve that controls the flow of fuel to the common rail.
SCV Suction control valve SCV Suction control valve
Installed on the supply pump. Installed on the supply pump.

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About Wiring Colors About Wiring Colors
All harnesses are distinguished through the color of their wire coating.In some electrical systems, the main circuit is distinguished All harnesses are distinguished through the color of their wire coating.In some electrical systems, the main circuit is distinguished
with a single color and the sub-circuits of the main circuit are distinguished with color stripes.Size and color in the wiring diagrams with a single color and the sub-circuits of the main circuit are distinguished with color stripes.Size and color in the wiring diagrams
are indicated using the following method. are indicated using the following method.

e.g. e.g.
Red (stripe color) Red (stripe color)
Green (base color) Green (base color)
2 2 2 2
size (0.5 mm
Harness size(0.5mm )) size (0.5 mm
Harness size(0.5mm ))

Name Name
1. Single color 1. Single color
2. Color stripe 2. Color stripe

Symbol Color Symbol Color Symbol Color Symbol Color


B Black BR Brown B Black BR Brown
W White LG Light green W White LG Light green
R Red GR Gray R Red GR Gray
G Green P Peach G Green P Peach
Y Yellow SB Sky blue Y Yellow SB Sky blue
L Blue V Violet L Blue V Violet
O Orange O Orange

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4023-8 4023-8
Reading Block Diagrams Reading Block Diagrams
Engine side Engine side
Block diagram Block diagram

EGR MOTOR EGR MOTOR

EGR POSITION SENSOR EGR POSITION SENSOR

COMMONRAIL PRESS. COMMONRAIL PRESS.


SENSOR SENSOR

CAM ANGLE SENSOR CAM ANGLE SENSOR

SHIELD SHIELD

     655#
     655#

1 ECM terminal No. 1 ECM terminal No.


2 Wiring color and wiring No. 2 Wiring color and wiring No.
3 Frame harness 3 Frame harness
4 Connector No. 4 Connector No.
5 Engine harness 5 Engine harness

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Main unit side Main unit side

Block diagram Block diagram

CONTROLLER A CONTROLLER A

PRESS. SENSOR (P1) PRESS. SENSOR (P1)

         
655# 655#

1 Computer A connector and terminal No. 1 Computer A connector and terminal No.
2 Wiring color and wiring No. 2 Wiring color and wiring No.
3 In-cab harness 3 In-cab harness
4 Connector No. 4 Connector No.
5 Frame harness 5 Frame harness

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4023-10 4023-10
Reading Trouble Diagnosis Reading Trouble Diagnosis
The diagram below is excerpted from trouble diagnosis.See the diagram and the explanation on the next page. The diagram below is excerpted from trouble diagnosis.See the diagram and the explanation on the next page.
Engine side trouble diagnosis Engine side trouble diagnosis
Trouble diagnosis page explanation Trouble diagnosis page explanation
The numbers listed below correspond to numbers in the diagram and an explanation for each is listed. The numbers listed below correspond to numbers in the diagram and an explanation for each is listed.

       

Diagnostic Trouble Code: 0087 Diagnostic Trouble Code: 0087


Abnormally Low Common Rail Pressure (supply pump not sending pressure) Abnormally Low Common Rail Pressure (supply pump not sending pressure)

Large amount of engine vibration, unstable idling speed Large amount of engine vibration, unstable idling speed

Output reduction, black smoke product, and excess output Output reduction, black smoke product, and excess output
are possible. are possible.

 Step 1  Step 1
Perform an actual machine diagnosis service support check. Perform an actual machine diagnosis service support check.

No Go to “Service No Go to “Service
Is the action complete? Is the action complete?
support” support”
Step 2 Step 2
Insert the fuel system. Yes Insert the fuel system. Yes
1. In the high-pressure and low-pressure lines, inspect for 1. In the high-pressure and low-pressure lines, inspect for
looseness in connections (fuel leaking), crushing, and looseness in connections (fuel leaking), crushing, and
clogging. clogging.
2. Inspect for any freezing or waxing in the fuel line, fuel fil- No 2. Inspect for any freezing or waxing in the fuel line, fuel fil- No
ter and fuel tank. Is the fuel system normal? ter and fuel tank. Is the fuel system normal?
3. Inspect wheather foreign matter is clogged in the feed 3. Inspect wheather foreign matter is clogged in the feed
pipe inside the fuel tank. Yes pipe inside the fuel tank. Yes

Step 3 Step 3
Perform repair or replacement for any locations where prob- Perform repair or replacement for any locations where prob-
lems are found. lems are found.

Is the action complete? Is the action complete?

Yes Yes
Go to step 18 Go to step 18

Step 4 Step 4
Check on the oil level gauge whether the oil level has risen, Check on the oil level gauge whether the oil level has risen,
and check for diesel odors. and check for diesel odors.

655#' 655#'

Diagnostic trouble code Diagnostic trouble code


1 1
Indicates the diagnostic trouble code number. Indicates the diagnostic trouble code number.
Diagnostic trouble code name Diagnostic trouble code name
2 2
Shows the name of the trouble. Shows the name of the trouble.
System condition that constitute diagnostic trou- System condition that constitute diagnostic trou-
3 3
ble code ble code
Primary problems Primary problems
4 4
Expected engine conditions due to system trouble Expected engine conditions due to system trouble
Trouble diagnosis steps Trouble diagnosis steps
5 Trouble diagnosis inspection, checking proce- 5 Trouble diagnosis inspection, checking proce-
dures dures

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4023-11 4023-11

 Block diagram.  Block diagram.

OIL PRESS. SENSOR OIL PRESS. SENSOR

WATER TEMP. SENSOR WATER TEMP. SENSOR

FUEL TEMP. SENSOR FUEL TEMP. SENSOR

CRANK ANGLE SENSOR CRANK ANGLE SENSOR

 Recovery from failure.  Recovery from failure.


• Fault judgement needs 3 to 10 minutes. • Fault judgement needs 3 to 10 minutes.
 Preconditions when DTC is set.  Preconditions when DTC is set.
• Key switch input voltage is 18 V or more. • Key switch input voltage is 18 V or more.
• DTC: 1630 or 1633 is not detected. • DTC: 1630 or 1633 is not detected.
 Diagnostic aid.  Diagnostic aid.
• DTC may be set at a overheat condition. • DTC may be set at a overheat condition.
• After starting the engine, the thermostat begins to open when the engine coolant temperature rises • After starting the engine, the thermostat begins to open when the engine coolant temperature rises
(85 °C), and the engine coolant temperature is stabilized. (85 °C), and the engine coolant temperature is stabilized.
• To make sure the correct performance of the ECT sensor, check with various temperatures using the • To make sure the correct performance of the ECT sensor, check with various temperatures using the
reckoner table between temperature and resistance. reckoner table between temperature and resistance.
If the sensor is faulty, operationality may be affected. If the sensor is faulty, operationality may be affected.
If the intermittent trouble is suspected, followings may be the cause. If the intermittent trouble is suspected, followings may be the cause.
• Improper connection of harness connector. • Improper connection of harness connector.
• Defective harness routing. • Defective harness routing.
• Worn harness cladding. • Worn harness cladding.
• Wire disconnection inside harness cladding. • Wire disconnection inside harness cladding.
655#' 655#'

Circuit explanation Circuit explanation


6 6
System circuit diagram related to trouble System circuit diagram related to trouble
Recovery from failure Recovery from failure
7 7
Record of recovery to normal operation after trouble was eliminated. Record of recovery to normal operation after trouble was eliminated.
Preconditions when diagnostic trouble code is set Preconditions when diagnostic trouble code is set
8 8
Conditions for judging presence of trouble with preconditions met. Conditions for judging presence of trouble with preconditions met.
Diagnostic aid Diagnostic aid
All of the causes of expected trouble are listed, and important ideas for diagnosis are All of the causes of expected trouble are listed, and important ideas for diagnosis are
9 9
gathered. gathered.
Make sure to read this before trouble diagnosis. Make sure to read this before trouble diagnosis.

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4023-12 4023-12

 Breaker box inspection procedure.  Breaker box inspection procedure.


Perfom the inspection in the following procedure if there is such an instruction to use breaker box in the step. Perfom the inspection in the following procedure if there is such an instruction to use breaker box in the step.
After inspection, return to the diagnostic step. After inspection, return to the diagnostic step.

Name Name
1. Breaker box 1. Breaker box
2. DMM 2. DMM

Step Item to be checked Inspection method Measuring condition Terminal No. Normal value Abnormal vaule Step Item to be checked Inspection method Measuring condition Terminal No. Normal value Abnormal vaule

11, 23 Short circuit to other Voltage measurement • Disconnect the sensor 82 - GND 0V 1 V or more 11, 23 Short circuit to other Voltage measurement • Disconnect the sensor 82 - GND 0V 1 V or more
signal circuit connector. 90 - GND signal circuit connector. 90 - GND
• Key switch “ON”. • Key switch “ON”.

Breaker box inspection procedure Breaker box inspection procedure


10 Contains table corresponding to trouble diagnosis steps and detailed 10 Contains table corresponding to trouble diagnosis steps and detailed
diagnosis procedures are listed. diagnosis procedures are listed.

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4023-13 4023-13

 On-board check procedure for sensors.  On-board check procedure for sensors.

Name Name
1. Breaker box 1. Breaker box
2. DMM 2. DMM
3. Sensor connector 3. Sensor connector
4. Engine harness 4. Engine harness
1. Disconnect the coupling connector, and check the sensor from engine harness connector. 1. Disconnect the coupling connector, and check the sensor from engine harness connector.
2. Disconnect the connector from sensor, and short the wiring of sensor connector. 2. Disconnect the connector from sensor, and short the wiring of sensor connector.
3. Check the harness from coupling connector for open circuit. 3. Check the harness from coupling connector for open circuit.
If both steps 1 and 2 are faulty, repair the harness. If both steps 1 and 2 are faulty, repair the harness.
Check from step 1 again. Check from step 1 again.
If only step 1 is faulty, replace the sensor. If only step 1 is faulty, replace the sensor.

Inspection procedures for sensors on machine Inspection procedures for sensors on machine
11 Perform trouble diagnosis and inspection for the sensors from the 11 Perform trouble diagnosis and inspection for the sensors from the
engine harness interconnected connectors. engine harness interconnected connectors.

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4023-14 4023-14
Main unit side trouble diagnosis Main unit side trouble diagnosis
Diagnostic trouble code diagnosis page explanation Diagnostic trouble code diagnosis page explanation
The numbers listed below correspond to numbers in the diagram and an explanation for each is listed. The numbers listed below correspond to numbers in the diagram and an explanation for each is listed.

 
 DTC: 7000 P1 Pressure sensor signal fault  DTC: 7000 P1 Pressure sensor signal fault

 P1 pressure sensor signal faulty.  P1 pressure sensor signal faulty.

Turn the key switch to “ON”. Turn the key switch to “ON”.

 The DTC: 7000 is displayed.  The DTC: 7000 is displayed.

Check the connected condition Check the connected condition


of each connector. of each connector.

Check the output voltage of P1 No 0.25 V Check the output voltage of P1 No 0.25 V
pressure sensor at a screen of the or less pressure sensor at a screen of the or less
“Service and Support”. “Service and Support”.
4.75 V or more 4.75 V or more

CHK H/W-A 3 Pot4 0000 V Yes CHK H/W-A 3 Pot4 0000 V Yes
 
Pot1 0000 V Pot5 0000 V
A Pot1 0000 V Pot5 0000 V
A
Pot2 0000 V Pot6 0000 V To A Pot2 0000 V Pot6 0000 V To A

Pot3 0000 V Pot7 0000 V Pot3 0000 V Pot7 0000 V

Check the short circuit to power Check the short circuit to power
supply. supply.

Disconnect the CN.115 after Disconnect the CN.115 after


turning the key switch to turning the key switch to
“OFF”. “OFF”.

Turn the key switch to “ON”. Turn the key switch to “ON”.

Cause/Procedure Cause/Procedure
Measure the voltage between No. 1 No Measure the voltage between No. 1 No
The harness W400 is faulty The harness W400 is faulty
terminal of the CN.115 harness and terminal of the CN.115 harness and
(short circuit). (short circuit).
“GND” “GND”
Replace Replace
Approx. 5 V Approx. 5 V

Yes Yes
Cause/Procedure Cause/Procedure
Measure the voltage between No. 2 No Measure the voltage between No. 2 No
The harness Y420 is faulty The harness Y420 is faulty
terminal 2 of the CN.115 harness and terminal 2 of the CN.115 harness and
(short circuit). (short circuit).
“GND” “GND”
Replace Replace
4.75 V or less 4.75 V or less

Yes Yes
Cause/Procedure Cause/Procedure
Measure the voltage between No. 3 No Measure the voltage between No. 3 No
terminal of the CN.115 harness and The harness BW440 is faulty terminal of the CN.115 harness and The harness BW440 is faulty
“GND” (short circuit). “GND” (short circuit).
0.25 V or less Replace 0.25 V or less Replace

Yes Yes
Cause/Procedure Cause/Procedure
The computer “A” faulty. The computer “A” faulty.
Replace 655# Replace 655#

Diagnostic trouble code Trouble diagnosis steps Diagnostic trouble code Trouble diagnosis steps
1 4 1 4
Indicates the diagnostic trouble code number. Trouble diagnosis inspection, checking procedures Indicates the diagnostic trouble code number. Trouble diagnosis inspection, checking procedures
Service support screen Service support screen
Diagnostic trouble code name Diagnostic trouble code name
2 5 Check the condition of trouble locations (voltage, 2 5 Check the condition of trouble locations (voltage,
Shows the name of the trouble. Shows the name of the trouble.
current, pressure, or the like). current, pressure, or the like).
Primary problems Primary problems
3 3
Expected conditions due to trouble Expected conditions due to trouble

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4023-15 4023-15

A A

Check the P1 pressure Check the P1 pressure


sensor sensor

Disconnect the CN. 115 after turning the key switch Disconnect the CN. 115 after turning the key switch
to “OFF”. to “OFF”.

Cause/Procedure Cause/Procedure

Measure the resistance between No. 1 No Measure the resistance between No. 1 No
terminal and No. 3 terminal of the CN.115 P1 pressure sensor is faulty. terminal and No. 3 terminal of the CN.115 P1 pressure sensor is faulty.
P1 pressure sensor. Replace P1 pressure sensor. Replace
Approx. 10k: Approx. 10k:

Yes Yes

Check the open circuit also the short circuit Check the open circuit also the short circuit
to “GND”. to “GND”.

Cause/Procedure Cause/Procedure

Check the electrical connection between No Check the electrical connection between No. 3 terminal No Check the electrical connection between No Check the electrical connection between No. 3 terminal No
The harness BW440 is faulty The harness BW440 is faulty
No. 1 terminal of the CN.115 harness and of the CN.115 harness and “GND”. No. 1 terminal of the CN.115 harness and of the CN.115 harness and “GND”.
(open circuit). (open circuit).
“GND”. “GND”.
Repair or replace Repair or replace
Check the electrical connection between There is and electrical connection. Check the electrical connection between There is and electrical connection.
No. 2 terminal of the CN.115 harness and No. 2 terminal of the CN.115 harness and
“GND”. Yes “GND”. Yes

There is and electrical connection. Turn the key switch to There is and electrical connection. Turn the key switch to
“ON”. “ON”.
Yes Yes

Cause/Procedure Cause/Procedure

Cause/Procedure Measure the voltage between No. 1 terminal of the No The harness W400 is faulty Cause/Procedure Measure the voltage between No. 1 terminal of the No The harness W400 is faulty
CN.115 harness and “GND”. (open circuit). CN.115 harness and “GND”. (open circuit).
The harness W400 and Approx. 5 V Repair or replace The harness W400 and Approx. 5 V Repair or replace
Y420 are faulty (short Y420 are faulty (short
circuit). Yes circuit). Yes
Replace Cause/Procedure Replace Cause/Procedure

Measure the voltage between No. 2 terminal of the No The harness Y420 is faulty Measure the voltage between No. 2 terminal of the No The harness Y420 is faulty
CN.115 harness and “GND”. (open circuit). CN.115 harness and “GND”. (open circuit).
0.25 V or more Repair or replace 0.25 V or more Repair or replace

Yes Yes

Cause/Procedure Cause/Procedure

The computer “A” is faulty. The computer “A” is faulty.


Replacement Replacement

Block diagram Block diagram


COMPUTER A COMPUTER A

 
PRESS. SENSOR (P1) PRESS. SENSOR (P1)

655# 655#

Circuit explanation Circuit explanation


6 6
System circuit diagram related to trouble System circuit diagram related to trouble

Lep NST-10-01-002-0EN Issued 10-2008 Lep NST-10-01-002-0EN Issued 10-2008


4023-16 4023-16

Cautions for Maintenance Cautions for Maintenance


Electrical System Caution: Electrical System Caution:
Follow the guidelines below to prevent damage caused Follow the guidelines below to prevent damage caused
Commercially available electrical components by the discharge of static electricity: Commercially available electrical components by the discharge of static electricity:
Commercially available electrical components refers to com- • Do not touch electrical component parts that have Commercially available electrical components refers to com- • Do not touch electrical component parts that have
mercially available electrical components that are installed on been soldered to the ECM connector pin or ECM cir- mercially available electrical components that are installed on been soldered to the ECM connector pin or ECM cir-
the main unit after shipping from the factory. As no particular cuit board. the main unit after shipping from the factory. As no particular cuit board.
consideration is given to installation of these components dur- consideration is given to installation of these components dur-
• Do not open the packaging for replacement parts • Do not open the packaging for replacement parts
ing the design phase of the main unit, use caution with these ing the design phase of the main unit, use caution with these
until preparations for the installation of those parts until preparations for the installation of those parts
components. components.
is complete. is complete.
Caution: • Before removing parts from their packaging, con- Caution: • Before removing parts from their packaging, con-
Commercially available electrical components, along nect the packaging with the normal ground of the Commercially available electrical components, along nect the packaging with the normal ground of the
with their respective power supplies and grounds, main unit. with their respective power supplies and grounds, main unit.
should be connected to a circuit that does not affect the • When handling parts while sliding across the seat, should be connected to a circuit that does not affect the • When handling parts while sliding across the seat,
electrical control system circuit. going from a standing position to a sitting one, or electrical control system circuit. going from a standing position to a sitting one, or
Commercially available electrical components, even ones walking a fixed distance, touch the parts to the nor- Commercially available electrical components, even ones walking a fixed distance, touch the parts to the nor-
that are normally installed, may cause function problems in mal ground before installing them. that are normally installed, may cause function problems in mal ground before installing them.
the electronic control system. This also includes devices that the electronic control system. This also includes devices that
are not connected to the electrical component system of the
Fuel Injection System are not connected to the electrical component system of the
Fuel Injection System
main unit such as hand-held phones and radios. Accordingly, Fuel line main unit such as hand-held phones and radios. Accordingly, Fuel line
when diagnosing problems with the powertrain, first check when diagnosing problems with the powertrain, first check
that there are none of these types of commercially available that there are none of these types of commercially available
electrical components mounted on the machine and remove electrical components mounted on the machine and remove
any that are mounted. If a problem has still not been resolved any that are mounted. If a problem has still not been resolved
after components have been removed, perform diagnosis after components have been removed, perform diagnosis
using the normal procedures. using the normal procedures.
Main unit welding Main unit welding
When performing welding on the main unit, be sure to discon- When performing welding on the main unit, be sure to discon-
nect the battery before performing welding. Failure to do so nect the battery before performing welding. Failure to do so
can lead to trouble or damage occurring with the electrical can lead to trouble or damage occurring with the electrical
control system due to the current produced during welding. control system due to the current produced during welding.
Damage due to discharge of static electricity Damage due to discharge of static electricity
Due to the fact that the electrical component parts used in the Due to the fact that the electrical component parts used in the
electrical control system are set in order to operate at an electrical control system are set in order to operate at an
extremely low voltage, they can easily be damaged by the extremely low voltage, they can easily be damaged by the
discharge of static electricity. Some electrical components discharge of static electricity. Some electrical components
may even be damaged by static electricity of 100 V or lower, may even be damaged by static electricity of 100 V or lower,
which is not felt by people. For a person to detect the dis- which is not felt by people. For a person to detect the dis-
charge of static electricity, 4000 V volts is necessary. charge of static electricity, 4000 V volts is necessary.
There are several methods in which people generate static There are several methods in which people generate static
electricity. The most general methods of an electrical charge electricity. The most general methods of an electrical charge
are friction and induction. Name are friction and induction. Name
• An example of an electrical charge created through fric-
1. Injector pipe • An example of an electrical charge created through fric-
1. Injector pipe
tion is when static electricity occurs when a person slide 2. Common rail tion is when static electricity occurs when a person slide 2. Common rail
occurs the seat of the main unit. 3. Common rail pressure sensor occurs the seat of the main unit. 3. Common rail pressure sensor
• An example of an electrical charge created through 4. Pressure limiter • An example of an electrical charge created through 4. Pressure limiter
induction is when a person wearing insulated shoes induction is when a person wearing insulated shoes
stands near a highly-charged object and static electricity • Do not reuse fuel system high-pressure lines or injector stands near a highly-charged object and static electricity • Do not reuse fuel system high-pressure lines or injector
occurs momentarily when the ground is touched. An out- pipes. If they are removed, replace them with new parts. occurs momentarily when the ground is touched. An out- pipes. If they are removed, replace them with new parts.
flow charge of the same polarity occurs and that person • Do not replace a pressure limiter, fuel temperature sen- flow charge of the same polarity occurs and that person • Do not replace a pressure limiter, fuel temperature sen-
becomes electrically-charged with a highly opposite sor or flow damper alone. If there is any problem, becomes electrically-charged with a highly opposite sor or flow damper alone. If there is any problem,
polarity. Static electricity will cause damage, so it is replace the common rail assembly and all the fuel lines. polarity. Static electricity will cause damage, so it is replace the common rail assembly and all the fuel lines.
important to exercise caution when handling electrical important to exercise caution when handling electrical
component parts and performing tests. component parts and performing tests.

Lep NST-10-02-005-0EN Issued 10-2008 Lep NST-10-02-005-0EN Issued 10-2008


4023-17 4023-17

How to Proceed with Trouble Diagnosis How to Proceed with Trouble Diagnosis
Trouble Diagnosis Procedure Trouble Diagnosis Procedure
Step 1 Confirm the customer complaint Step 1 Confirm the customer complaint
• Use an inquiry sheet to clarify the status of the trouble. • Use an inquiry sheet to clarify the status of the trouble.
Step 2 Implement preliminary maintenance Step 2 Implement preliminary maintenance
• Implement overall visual inspection. • Implement overall visual inspection.
• Check past maintenance records. • Check past maintenance records.
• Detect any abnormal sounds or smells. • Detect any abnormal sounds or smells.
• Collect trouble code (diagnostic trouble code) information in order to perform effective repair. • Collect trouble code (diagnostic trouble code) information in order to perform effective repair.
• Compare with reference values and inspect to see if there are any abnormalities. • Compare with reference values and inspect to see if there are any abnormalities.
Step 3 Confirm service information Step 3 Confirm service information
• Check parts and service bulletins, quick quality information, and service work sheets. • Check parts and service bulletins, quick quality information, and service work sheets.
Step 4 Implement inspection for each diagnostic trouble code Step 4 Implement inspection for each diagnostic trouble code
• Perform inspection for each displayed diagnostic trouble code item. • Perform inspection for each displayed diagnostic trouble code item.
Step 5 Implement a problem inspection for each symptom. Step 5 Implement a problem inspection for each symptom.
• Perform inspection for items in which a diagnostic trouble code is not displayed. • Perform inspection for items in which a diagnostic trouble code is not displayed.
Trubleshoot
Useful information: Trubleshoot
Useful information:
Engine-side Trouble........................................................................................................................................... 89
DTC: List of Diagnostic Trouble Codes............................................................................................................. 89
About recovery from failure ............................................................................................................................... 99
Types of system trouble diagnosis Engine-side Trouble........................................................................................................................................... 89
DTC: List of Diagnostic Trouble Codes............................................................................................................. 89
About recovery from failure ............................................................................................................................... 99
Types of system trouble diagnosis
Screen Display Details .................................................................................................................................... 100 Screen Display Details .................................................................................................................................... 100
Trouble Display ............................................................................................................................................... 102 Trouble Display ............................................................................................................................................... 102
DTC:0087 Common rail low pressure fault (No pressure feed in supply pump) ............................................. 103
The system diagnosis method is a standardized method for DTC:0087 Common rail low pressure fault (No pressure feed in supply pump) ............................................. 103
The system diagnosis method is a standardized method for
1 DTC:0088 Common rail pressure is abnormally high (1st or 2nd stage) ........................................................ 109
DTC:0089 Common rail pressure fault (Excessive pressure feed in supply pump)........................................ 113
DTC:0090 SCV drive system open circuit, +B short or ground short .............................................................. 117
repairing all E/E systems.In contrast with general main unit
1 DTC:0088 Common rail pressure is abnormally high (1st or 2nd stage) ........................................................ 109
DTC:0089 Common rail pressure fault (Excessive pressure feed in supply pump)........................................ 113
DTC:0090 SCV drive system open circuit, +B short or ground short .............................................................. 117
repairing all E/E systems.In contrast with general main unit
DTC:0107 Barometric pressure sensor circuit fault (low voltage fault) ........................................................... 122 DTC:0107 Barometric pressure sensor circuit fault (low voltage fault) ........................................................... 122
DTC:0380 Glow relay circuit fault................................................................................240
DTC:0108 Barometric pressure sensor fault (high voltage fault) .................................................................... 128 DTC:0380 Glow relay circuit fault................................................................................240
DTC:0108 Barometric pressure sensor fault (high voltage fault) .................................................................... 128
DTC:0487 EGR position sensor faultDTC:0112

DTC:0522 Engine oil pressure sensor


..........................................................................246
IAT (Intake air temperature) sensor fault (low voltage fault).......................................................... 133
DTC:0488 EGR valve control fault ..............................................................................251
DTC:0113 IAT(Intake air temperature) sensor fault (high voltage fault) ......................................................... 139
fault (lowEnginevoltagecoolant
fault) ................................... 256 (low voltage fault).......................................................... 145
trouble, E/E system trouble often occurs in the steps listed DTC:0487 EGR position sensor faultDTC:0112

DTC:0522 Engine oil pressure sensor


..........................................................................246
IAT (Intake air temperature) sensor fault (low voltage fault).......................................................... 133
DTC:0488 EGR valve control fault ..............................................................................251
DTC:0113 IAT(Intake air temperature) sensor fault (high voltage fault) ......................................................... 139
fault (lowEnginevoltagecoolant
fault) ................................... 256 (low voltage fault).......................................................... 145
trouble, E/E system trouble often occurs in the steps listed
DTC:0117 temperature sensor fault DTC:0117 temperature sensor fault
DTC:0523 Engine oil pressure sensor fault (high
DTC:0118 voltage
Engine fault)..................................261
coolant temperature sensor fault (high voltage fault) ........................................................ 152
DTC:0601 ROM fault...................................................................................................267
DTC:0182 FT (Fuel temperature) sensor fault (low voltage fault)................................................................... 159
DTC:0603 EEPROM fault ..................................................................................
DTC:0183 FT (Fuel temperature) sensor fault ......... 268 voltage fault) ................................................................. 166
(high
below. DTC:0523 Engine oil pressure sensor fault (high
DTC:0118 voltage
Engine fault)..................................261
coolant temperature sensor fault (high voltage fault) ........................................................ 152
DTC:0601 ROM fault...................................................................................................267
DTC:0182 FT (Fuel temperature) sensor fault (low voltage fault)................................................................... 159
DTC:0603 EEPROM fault ..................................................................................
DTC:0183 FT (Fuel temperature) sensor fault ......... 268 voltage fault) ................................................................. 166
(high
below.
DTC:0606 CPU fault ...................................................................................................269
DTC:0192 Common rail pressure sensor fault (low voltage fault)................................................................... 173 DTC:0606 CPU fault ...................................................................................................269
DTC:0192 Common rail pressure sensor fault (low voltage fault)................................................................... 173
DTC:0193 Common rail pressure sensor fault (high voltage fault) ................................................................. 179
DTC:0201 Open circuit in No.1 injection nozzle drive system ........................................................................ 185
1. Initial stage of trouble: DTC:0193 Common rail pressure sensor fault (high voltage fault) ................................................................. 179
DTC:0201 Open circuit in No.1 injection nozzle drive system ........................................................................ 185
1. Initial stage of trouble:
DTC:0202 Open circuit in No.2 injection nozzle drive system ........................................................................ 190
DTC:0203 Open circuit in No.3 injection nozzle drive system ........................................................................ 195
DTC:0204 Open circuit in No.4 injection nozzle drive system ........................................................................ 200
2 • Trouble occurs over a single time over a short
DTC:0202 Open circuit in No.2 injection nozzle drive system ........................................................................ 190
DTC:0203 Open circuit in No.3 injection nozzle drive system ........................................................................ 195
DTC:0204 Open circuit in No.4 injection nozzle drive system ........................................................................ 200
2 • Trouble occurs over a single time over a short
DTC:0219 Overrun.......................................................................................................................................... 205 DTC:0219 Overrun.......................................................................................................................................... 205
DTC:0237 Boost pressure sensor fault (low voltageTrouble fault).............................................................................. 207
symptom .........................................................................................................429 DTC:0237 Boost pressure sensor fault (low voltageTrouble fault).............................................................................. 207
symptom .........................................................................................................429
DTC:0238 Boost pressure sensor fault (high voltage Trouble
DTC:0335 CKP (crankshaft position) sensor fault (noEngine
fault) ............................................................................
signal).........................................................................
213
symptom ........................................................................................................429
219
start failure ......................................................................................................430
period, and the customer often is not aware of the DTC:0238 Boost pressure sensor fault (high voltage Trouble
DTC:0335 CKP (crankshaft position) sensor fault (noEngine
fault) ............................................................................ 213
symptom ........................................................................................................429
signal)......................................................................... 219
start failure ......................................................................................................430
period, and the customer often is not aware of the
DTC:0336 CKP (crankshaft position) sensor fault (signal Enginefault)...................................................................... 224
stall..................................................................................................................433 DTC:0336 CKP (crankshaft position) sensor fault (signal Enginefault)...................................................................... 224
stall..................................................................................................................433
DTC:0340 CMP (camshaft position) sensor fault (no Engine
DTC:0341 CMP (camshaft position) sensor fault (signal
signal) ..........................................................................
fault)output
Engine .......................................................................
229
hunting, rough idling........................................................................................436
235
shortage ...............................................................................................439
trouble.Customer complaints at this stage are unspe- DTC:0340 CMP (camshaft position) sensor fault (no Engine
DTC:0341 CMP (camshaft position) sensor fault (signal
signal) ..........................................................................
fault)output
Engine .......................................................................
229
hunting, rough idling........................................................................................436
235
shortage ...............................................................................................439
trouble.Customer complaints at this stage are unspe-
DTC:0380 Glow relay circuit fault.................................................................................................................... 240
Exhaust gas contains a lot of white smoke .................................................................442 DTC:0380 Glow relay circuit fault.................................................................................................................... 240
Exhaust gas contains a lot of white smoke .................................................................442
DTC:0487 EGR position sensor fault ..............................................................................................................
DTC:0488 EGR valve control fault ..................................................................................................................
246
Exhaust gas contains a lot of black smoke .................................................................444
251
Noise ...........................................................................................................................446
cific and problems are difficult to recreate.However, DTC:0487 EGR position sensor fault .............................................................................................................. 246
Exhaust gas contains a lot of black smoke .................................................................444
DTC:0488 EGR valve control fault .................................................................................................................. 251
Noise ...........................................................................................................................446
cific and problems are difficult to recreate.However,
DTC:0522 Engine oil pressure sensor fault (low voltage Fuelfault) .......................................................................
consumption 256
deteriorates.................................................................................... 448 DTC:0522 Engine oil pressure sensor fault (low voltage Fuelfault) .......................................................................
consumption 256
deteriorates.................................................................................... 448
DTC:0523 Engine oil pressure sensor fault (high voltage fault)......................................................................
Oil consumption
DTC:0601 ROM fault.......................................................................................................................................
261
deteriorates ......................................................................................451
267
Tech2 reference value .................................................................................................453
DTC:0603 EEPROM fault ............................................................................................................................... 268
trouble is sometimes recorded by the engine control DTC:0523 Engine oil pressure sensor fault (high voltage fault)......................................................................
Oil consumption 261
deteriorates ......................................................................................451
DTC:0601 ROM fault....................................................................................................................................... 267
Tech2 reference value .................................................................................................453
DTC:0603 EEPROM fault ............................................................................................................................... 268
trouble is sometimes recorded by the engine control
DTC:0606 CPU fault ....................................................................................................................................... 269
DTC:0611 Charge circuit fault (bank 1)........................................................................................................... 270
DTC:0612 Charge circuit fault (bank 2)........................................................................................................... 273
module (ECM) in this stage. DTC:0606 CPU fault ....................................................................................................................................... 269
DTC:0611 Charge circuit fault (bank 1)........................................................................................................... 270
DTC:0612 Charge circuit fault (bank 2)........................................................................................................... 273
module (ECM) in this stage.
DTC:1093 No pump pressure feed ................................................................................................................. 276
= Past problem (past trouble) DTC:1093 No pump pressure feed ................................................................................................................. 276
= Past problem (past trouble)
Trouble symptom ............................................................................................................................................. 429
Trouble symptom ............................................................................................................................................ 429
Engine start failure .......................................................................................................................................... 430
2. Mid-term stage of trouble: Trouble symptom ............................................................................................................................................. 429
Trouble symptom ............................................................................................................................................ 429
Engine start failure .......................................................................................................................................... 430
2. Mid-term stage of trouble:
Engine stall...................................................................................................................................................... 433 Engine stall...................................................................................................................................................... 433
Engine hunting, rough idling............................................................................................................................ 436
Engine output shortage ................................................................................................................................... 439
• Trouble occurs a single time over a short period but Engine hunting, rough idling............................................................................................................................ 436
Engine output shortage ................................................................................................................................... 439
• Trouble occurs a single time over a short period but
Exhaust gas contains a lot of white smoke ..................................................................................................... 442 Exhaust gas contains a lot of white smoke ..................................................................................................... 442
Exhaust gas contains a lot of black smoke ..................................................................................................... 444
Noise ............................................................................................................................................................... 446 repeats intermittently, and always occurs during spe- Exhaust gas contains a lot of black smoke ..................................................................................................... 444
Noise ............................................................................................................................................................... 446 repeats intermittently, and always occurs during spe-
Fuel consumption deteriorates........................................................................................................................ 448 Fuel consumption deteriorates........................................................................................................................ 448
Oil consumption deteriorates .......................................................................................................................... 451
Tech2 reference value ..................................................................................................................................... 453 cific conditions.Customer complaints (trouble Oil consumption deteriorates .......................................................................................................................... 451
Tech2 reference value ..................................................................................................................................... 453 cific conditions.Customer complaints (trouble
TSWG0156E TSWG0156E
descriptions) are specific and the description of trou- descriptions) are specific and the description of trou-
Name ble conditions is unspecific. Name ble conditions is unspecific.
1. Diagnostic trouble code Diagnosis for each code Therefore, the person diagnosing the main unit can 1. Diagnostic trouble code Diagnosis for each code Therefore, the person diagnosing the main unit can
2. Problem symptom list recreate the trouble through understanding the trou- 2. Problem symptom list recreate the trouble through understanding the trou-
ble conditions. ble conditions.
= Intermittent problem = Intermittent problem
3. Stage at which trouble is recognized as actually occur- 3. Stage at which trouble is recognized as actually occur-
ring: ring:
• Trouble occurrence is fixed and constant, and cus- • Trouble occurrence is fixed and constant, and cus-
tomer complaints are real and specific. tomer complaints are real and specific.
Therefore, the person diagnosing the main unit can Therefore, the person diagnosing the main unit can
recreate the trouble.However, the cause of the trou- recreate the trouble.However, the cause of the trou-
ble occurrence is sometimes complex with 2 or more ble occurrence is sometimes complex with 2 or more
causes present. causes present.
= Current problem (current trouble) = Current problem (current trouble)

Lep NST-10-03-004-0EN Issued 10-2008 Lep NST-10-03-004-0EN Issued 10-2008


4023-18 4023-18
Inquiry Trouble diagnosis inquiry sheet Inquiry Trouble diagnosis inquiry sheet
Inquiry When receiving a main unit from the customer at a service Inquiry When receiving a main unit from the customer at a service
plant, it is necessary to confirm the trouble symptoms and plant, it is necessary to confirm the trouble symptoms and
1. Use an inquiry sheet in order to fully understand the cus- trouble occurrence data based on the trouble diagnosis 1. Use an inquiry sheet in order to fully understand the cus- trouble occurrence data based on the trouble diagnosis
tomer's stated description. inquiry sheet. tomer's stated description. inquiry sheet.
Note: Note:
Inquiry is not done in a haphazard manner. Inquiry is done to Inquiry is not done in a haphazard manner. Inquiry is done to
narrow down inspection from the problem symptoms (actual narrow down inspection from the problem symptoms (actual
conditions) to an assumed problem. conditions) to an assumed problem.

2. Judge trouble information accurately. 2. Judge trouble information accurately.


Concretely understand trouble using 5W1H as a basis. Concretely understand trouble using 5W1H as a basis.
Ex.: Low temperature, during starting, during normal 1 Ex.: Low temperature, during starting, during normal 1
operation, near the engine area, metal sound. operation, near the engine area, metal sound.

Inquiry key points Inquiry key points

· What Problem symptoms 2 · What Problem symptoms 2

Date, time, occurrence fre- Date, time, occurrence fre-


· When · When
quency quency
· Where Road circumstances · Where Road circumstances
Travel conditions, operating Travel conditions, operating
· In what kind of situation · In what kind of situation
conditions, weather conditions, weather
· What happened How were symptoms detected · What happened How were symptoms detected
Name Name
1. Trouble symptoms 1. Trouble symptoms
2. Trouble frequency, trouble conditions 2. Trouble frequency, trouble conditions

Reasons for inquiry: Reasons for inquiry:


• Problem symptoms cannot always be recreated at the • Problem symptoms cannot always be recreated at the
service plant. service plant.
• Customer complaints are not necessarily limited to trou- • Customer complaints are not necessarily limited to trou-
ble. ble.
• If the repair supervisor is not given correct information • If the repair supervisor is not given correct information
about trouble conditions, this will result in wasted repair about trouble conditions, this will result in wasted repair
man-hours. man-hours.
• The inquiry sheet is an aid for main unit diagnosis, • The inquiry sheet is an aid for main unit diagnosis,
repair, and repair confirmation at the service plant. repair, and repair confirmation at the service plant.

Lep NST-10-03-004-0EN Issued 10-2008 Lep NST-10-03-004-0EN Issued 10-2008


4023-19 4023-19
Engine control system questionnaire Engine control system questionnaire
Company of inspector __________________________________________________ Company of inspector __________________________________________________
Name of inspector _____________________________________________________ Name of inspector _____________________________________________________

User User’s name Machine application User User’s name Machine application

Address: Address:

Machine Date of diagnosis: ________Year ________ Month _________Day Date of delivery: ________Year ________ Month _________Day Machine Date of diagnosis: ________Year ________ Month _________Day Date of delivery: ________Year ________ Month _________Day

Operating period: Present ________hours (When trouble occurs ________ hours) Date of trouble occurrence:________Year _______ Month Operating period: Present ________hours (When trouble occurs ________ hours) Date of trouble occurrence:________Year _______ Month
_______Day _______Day
Machine model Machine serial No. Machine model Machine serial No.

Engine Engine model Engine serial No. Engine Engine model Engine serial No.

o Egine does not start o Egine does not crank o No first combustion o Incomplete combustion o Egine does not start o Egine does not crank o No first combustion o Incomplete combustion
o Difficult starting of engine o Engine cranks slowly: Take more than ________ sec. o Others (__________________________________) o Difficult starting of engine o Engine cranks slowly: Take more than ________ sec. o Others (__________________________________)
Trouble symptom

Trouble symptom
o Unstable idling o Abnormal idling o High (________ rpm) o Low (________ rpm) o Unstable idling o Abnormal idling o High (________ rpm) o Low (________ rpm)
o Rough idle (out of specified speed for full warm-up) o Others (__________________________________) o Rough idle (out of specified speed for full warm-up) o Others (__________________________________)
o Low machine operationally o Surging o Knocking o Low output o Others o Low machine operationally o Surging o Knocking o Low output o Others
o Abnormal smoke o Much black smoke o Much white smoke o Much bluish smoke o Others o Abnormal smoke o Much black smoke o Much white smoke o Much bluish smoke o Others
o Noise o Engine vibration sound (__________________ Circumference) o Noise in engine (___________________ Circumference) o Noise o Engine vibration sound (__________________ Circumference) o Noise in engine (___________________ Circumference)
o Engine stalls o Immediatly after starting o When accelerator is released o When A/C is operated o Engine stalls o Immediatly after starting o When accelerator is released o When A/C is operated
o When operating at full load o At certain operation mode o Others (__________________________________) o When operating at full load o At certain operation mode o Others (__________________________________)
o Vibration at idling o Vertical vibration o Horizontal vibration o Others (__________________________________) o Vibration at idling o Vertical vibration o Horizontal vibration o Others (__________________________________)

Frequency of trouble o Always o Sometimes (How many times _______________Date/Month) o Once Frequency of trouble o Always o Sometimes (How many times _______________Date/Month) o Once
o Others (________________________________________________________________________________________________) o Others (________________________________________________________________________________________________)
Weather o Fine o Cloudiness o Rain o Snow Weather o Fine o Cloudiness o Rain o Snow
o After lightening o Others (_________________________________________________________________) o After lightening o Others (_________________________________________________________________)
Ambient temperature o 30 °C or more o Around 20-30 °C o Around 10-20 °C o 0 °C or less (_________ °C) Ambient temperature o 30 °C or more o Around 20-30 °C o Around 10-20 °C o 0 °C or less (_________ °C)
Season o Spring o Summer o Autumn o Winter Season o Spring o Summer o Autumn o Winter
Location o Outdoor o Indoor o General road o Rough road Location o Outdoor o Indoor o General road o Rough road
Trouble Condition

Trouble Condition
o Expressway o Slope (Grade _______°) o Height (___m above sea level) o In mountain o Expressway o Slope (Grade _______°) o Height (___m above sea level) o In mountain
o On the sea o Harbor o Construction field (Type _____________________________) o On the sea o Harbor o Construction field (Type _____________________________)
o Roadworks field (Type __________________________________) o Others (_________________________________________) o Roadworks field (Type __________________________________) o Others (_________________________________________)
Engine temperature o Cold o During warm-up o After warm-up o Others (______________) Engine temperature o Cold o During warm-up o After warm-up o Others (______________)
Engine coolant/oil temp. o Engine coolant temperature (________ °C) o Engine oil temperature (________ °C) Engine coolant/oil temp. o Engine coolant temperature (________ °C) o Engine oil temperature (________ °C)
Operating condition o When starting o After starting (_______min.) o Idling o Racing Operating condition o When starting o After starting (_______min.) o Idling o Racing
o During operation o Constant speed o When engine speed rises o When engine speed lowers o During operation o Constant speed o When engine speed rises o When engine speed lowers
o A/C switch ON o A/C switch OFF o Others (_________________________________________) o A/C switch ON o A/C switch OFF o Others (_________________________________________)
Condition when trouble o After engine oil is replaced o After oil filter is replaced o After replenishment of fuel o After sediment is drained Condition when trouble o After engine oil is replaced o After oil filter is replaced o After replenishment of fuel o After sediment is drained
occurs occurs
o After operating on slope o After out of gas o After washing with HP o Others (______________) o After operating on slope o After out of gas o After washing with HP o Others (______________)
Oil used Maker (_____________________) Manufacturer (________________) Grade (___________________) Viscosity (________________) Oil used Maker (_____________________) Manufacturer (________________) Grade (___________________) Viscosity (________________)
Fuel type o Diesel fuel o Diesel fuel No. 1 o Diesel fuel special No.1 o Diesel fuel No. 2 Fuel type o Diesel fuel o Diesel fuel No. 1 o Diesel fuel special No.1 o Diesel fuel No. 2
o Diesel fuel special No.3 o Kerosene o A heavy oil o Others (______________) o Diesel fuel special No.3 o Kerosene o A heavy oil o Others (______________)

State of diag lamp o ON o Sometimes comes on o Not come on State of diag lamp o ON o Sometimes comes on o Not come on
Error Codes

Error Codes
Error codes Current o ______________________ o ______________________ o ______________________ o ______________________ Error codes Current o ______________________ o ______________________ o ______________________ o ______________________
code code
o ______________________ o ______________________ o ______________________ o ______________________ o ______________________ o ______________________ o ______________________ o ______________________
Past code o ______________________ o ______________________ o ______________________ o ______________________ Past code o ______________________ o ______________________ o ______________________ o ______________________
o ______________________ o ______________________ o ______________________ o ______________________ o ______________________ o ______________________ o ______________________ o ______________________
Past error history Date of error occurrence: _____ Year ______Month _____Day/ Description: (_____________________) Action to be taken: (_____________________) Past error history Date of error occurrence: _____ Year ______Month _____Day/ Description: (_____________________) Action to be taken: (_____________________)
Date of error occurrence: _____ Year ______Month _____Day/ Description: (_____________________) Action to be taken: (_____________________) Date of error occurrence: _____ Year ______Month _____Day/ Description: (_____________________) Action to be taken: (_____________________)

Others Others

Lep NST-10-03-004-0EN Issued 10-2008 Lep NST-10-03-004-0EN Issued 10-2008


4023-20 4023-20
Preliminary Inspection Trouble Diagnosis Preliminary Inspection Trouble Diagnosis
Visual inspection inside the engine room and Basic information on necessary tools Visual inspection inside the engine room and Basic information on necessary tools
housing frame important: housing frame important:
When implementing diagnosis procedures, a careful visual Implementing diagnosis procedures without basic When implementing diagnosis procedures, a careful visual Implementing diagnosis procedures without basic
inspection of the inside of the engine room and housing frame knowledge of this powertrain may result in wrong diag- inspection of the inside of the engine room and housing frame knowledge of this powertrain may result in wrong diag-
is performed.Problems can often be solved through this nosis or damage to powertrain component parts.If the is performed.Problems can often be solved through this nosis or damage to powertrain component parts.If the
inspection without taking unnecessary steps.When imple- person carrying out diagnosis has no basic knowledge of inspection without taking unnecessary steps.When imple- person carrying out diagnosis has no basic knowledge of
menting a visual inspection, follow the guidelines below. this powertrain, powertrain-related problem diagnosis menting a visual inspection, follow the guidelines below. this powertrain, powertrain-related problem diagnosis
• Inspect all air hoses to check that there are no punch must not be performed. A basic understanding of hand • Inspect all air hoses to check that there are no punch must not be performed. A basic understanding of hand
holes, cuts, or misaligned connections, and that appro- tools such as scan tools is necessary in order to effec- holes, cuts, or misaligned connections, and that appro- tools such as scan tools is necessary in order to effec-
priate lines are used. tively use the Service Manual. priate lines are used. tively use the Service Manual.
• Inspect hoses that are hidden by other component parts • Inspect hoses that are hidden by other component parts
Main unit diagnosis tests Main unit diagnosis tests
and difficult to see. and difficult to see.
There are the following types of problem diagnosis results. There are the following types of problem diagnosis results.
• Inspect all harnesses inside the engine room and hous- • Inspect all harnesses inside the engine room and hous-
1. Past trouble 1. Past trouble
ing frame to check that they are all connected properly, ing frame to check that they are all connected properly,
Diagnostic trouble codes that occur under the following Diagnostic trouble codes that occur under the following
none have burnt or worn areas, none are constricted, none have burnt or worn areas, none are constricted,
conditions are referred to as "Past trouble". conditions are referred to as "Past trouble".
none are touching sharp edges, and none are touching none are touching sharp edges, and none are touching
the high temperature exhaust manifold or pipes. • The diagnosis test of the previous ignition cycle is the high temperature exhaust manifold or pipes. • The diagnosis test of the previous ignition cycle is
complete. complete.
Confirmation of main unit maintenance • The machine passed the diagnosis test of the current Confirmation of main unit maintenance • The machine passed the diagnosis test of the current
condition ignition cycle. condition ignition cycle.
If clogging of the oil filter and fuel filter occurs or deposits • The problems identified in the diagnosis test are not If clogging of the oil filter and fuel filter occurs or deposits • The problems identified in the diagnosis test are not
adhere to the crank case due to insufficient engine oil chang- currently present. adhere to the crank case due to insufficient engine oil chang- currently present.
ing or use of an oil with an inappropriate viscosity, main unit ing or use of an oil with an inappropriate viscosity, main unit
2. Current trouble 2. Current trouble
problems that were not detected before the main unit diagno- problems that were not detected before the main unit diagno-
Diagnostic trouble codes that occur under the following Diagnostic trouble codes that occur under the following
sis system check may occur. sis system check may occur.
conditions are referred to as "Current trouble". conditions are referred to as "Current trouble".
Also, problems may occur if clogging of the suction filter or Also, problems may occur if clogging of the suction filter or
return filter occurs due to insufficient replacement of hydraulic • The previous ignition cycle diagnosis test is com- return filter occurs due to insufficient replacement of hydraulic • The previous ignition cycle diagnosis test is com-
oil or use an oil with an inappropriate viscosity.Main unit plete. oil or use an oil with an inappropriate viscosity.Main unit plete.
maintenance problems are not categorized in the category of • The problems identified in the diagnosis test are cur- maintenance problems are not categorized in the category of • The problems identified in the diagnosis test are cur-
trouble other than main unit trouble, but the main unit mainte- rently present. trouble other than main unit trouble, but the main unit mainte- rently present.
nance schedule is observed somewhat more strictly because • The problems are present in the current ignition nance schedule is observed somewhat more strictly because • The problems are present in the current ignition
main unit diagnosis is more sensitive. cycle. main unit diagnosis is more sensitive. cycle.
Non-genuine parts, after parts Non-genuine parts, after parts
All service support diagnosis adjustment is done for operation All service support diagnosis adjustment is done for operation
with genuine parts.Accordingly, if general commercially-avail- with genuine parts.Accordingly, if general commercially-avail-
able sensors or switches are installed, this will cause mis- able sensors or switches are installed, this will cause mis-
takes in diagnosis and false diagnostic trouble codes to takes in diagnosis and false diagnostic trouble codes to
display. display.
If a commercially-available electronic device such as a mobile If a commercially-available electronic device such as a mobile
phone, stereo or anti-theft device is inappropriately installed, phone, stereo or anti-theft device is inappropriately installed,
an EMI (electromagnetic interference) may be emitted to the an EMI (electromagnetic interference) may be emitted to the
control system.As a result, incorrect sensor information will control system.As a result, incorrect sensor information will
be generated and diagnostic trouble codes will display.When be generated and diagnostic trouble codes will display.When
performing trouble diagnosis, recheck problems after either performing trouble diagnosis, recheck problems after either
turning OFF power to or removing all commercially available turning OFF power to or removing all commercially available
parts. parts.
Useful information: Useful information:
Trouble with related systems Trouble with related systems
In most main unit diagnosis, the engine control module (ECM) In most main unit diagnosis, the engine control module (ECM)
will instruct the machine to enter the back-up operation mode will instruct the machine to enter the back-up operation mode
if the ECM or computer A detects trouble with a related sys- if the ECM or computer A detects trouble with a related sys-
tem or component part..If the machine enters back-up opera- tem or component part..If the machine enters back-up opera-
tion mode, output is reduced to protect the main unit. tion mode, output is reduced to protect the main unit.

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Terminology explanation Terminology explanation
Diagnostic trouble code Diagnostic trouble code
Each time that the key switch is turned ON, the ECM and Each time that the key switch is turned ON, the ECM and
computer A performs a self-test for most all of the wiring and computer A performs a self-test for most all of the wiring and
component parts. If a system problem is detected, this is component parts. If a system problem is detected, this is
saved in the memory of the ECM and computer A and back- saved in the memory of the ECM and computer A and back-
up control is performed depending on the diagnostic trouble up control is performed depending on the diagnostic trouble
code.Also, abnormalities that affect the shovel main unit will code.Also, abnormalities that affect the shovel main unit will
cause a message to be displayed to inform the operator. cause a message to be displayed to inform the operator.
Ignition cycle Ignition cycle
The ignition cycle refers to the machine operation cycle of The ignition cycle refers to the machine operation cycle of
turning the key ON, running the machine, and turning the key turning the key ON, running the machine, and turning the key
OFF used to satisfy the prescribed main unit diagnosis crite- OFF used to satisfy the prescribed main unit diagnosis crite-
ria. ria.
Data link connector (DLC) Data link connector (DLC)
The equipment for communicating with the control unit is a The equipment for communicating with the control unit is a
data link connector (DLC).Also, the DLC is provided in order data link connector (DLC).Also, the DLC is provided in order
to connect with scan tools.The general uses of scan tools are to connect with scan tools.The general uses of scan tools are
shown below. shown below.
• Identification of saved diagnostic trouble codes • Identification of saved diagnostic trouble codes
• Reading of serial data • Reading of serial data

Note: Note:
See the main unit manual as the DLC installation location and See the main unit manual as the DLC installation location and
whether or not there is a DLC will vary according to the shovel whether or not there is a DLC will vary according to the shovel
main unit. main unit.

ECM OFF ECM OFF


If the key switch is turned OFF, power to the ECM will be If the key switch is turned OFF, power to the ECM will be
completely turned OFF and the ECM will go into the ECM completely turned OFF and the ECM will go into the ECM
OFF state after about 10 sec. or more. OFF state after about 10 sec. or more.
Comprehensive diagnosis operations of Comprehensive diagnosis operations of
component parts monitoring component parts monitoring
To make the engine operate normally, comprehensive diag- To make the engine operate normally, comprehensive diag-
nosis of component parts is necessary. nosis of component parts is necessary.

Input component parts: Input component parts:


Confirm the input component parts in order to inspect for cir- Confirm the input component parts in order to inspect for cir-
cuit disconnections and values outside of the prescribed cuit disconnections and values outside of the prescribed
range. range.
The following are sensors for input component parts, but sen- The following are sensors for input component parts, but sen-
sors are not limited to just these. sors are not limited to just these.
• Crankshaft position (CKP) sensor • Crankshaft position (CKP) sensor
• Camshaft position (CMP) sensor • Camshaft position (CMP) sensor
• Coolant temperature sensor • Coolant temperature sensor
• Boost pressure sensor • Boost pressure sensor
• Common rail pressure sensor • Common rail pressure sensor

Output component parts: Output component parts:


Output component parts diagnose whether responses to con- Output component parts diagnose whether responses to con-
trol unit commands are appropriate or not.Confirm whether trol unit commands are appropriate or not.Confirm whether
there are any circuit disconnections and whether any values there are any circuit disconnections and whether any values
are outside the prescribed ranges. are outside the prescribed ranges.
The following are circuits in output components parts that are The following are circuits in output components parts that are
checked, but circuits are not limited to just these. checked, but circuits are not limited to just these.
• SCV • SCV
• Lamp, relay control • Lamp, relay control
• EGR valve • EGR valve

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Diagnostic Trouble Code Reading When trouble is not detected Diagnostic Trouble Code Reading When trouble is not detected
Procedure This status indicates that the main unit is judged to be operat- Procedure This status indicates that the main unit is judged to be operat-
ing normally.The status stated by the customer is sometimes ing normally.The status stated by the customer is sometimes
Diagnostic trouble code reading with the normal operation.The customer's complaint should be Diagnostic trouble code reading with the normal operation.The customer's complaint should be
trouble indicator monitor checked through comparison with a separate main unit that is trouble indicator monitor checked through comparison with a separate main unit that is
If a diagnostic trouble code occurs, a diagnostic trouble code operating normally.Depending on the situation, however, the If a diagnostic trouble code occurs, a diagnostic trouble code operating normally.Depending on the situation, however, the
and message will display in the main unit trouble indicator problem is sometimes an intermittent one.Before returning and message will display in the main unit trouble indicator problem is sometimes an intermittent one.Before returning
monitor. the main unit, the complaint should be checked in the status monitor. the main unit, the complaint should be checked in the status
stated by the customer. stated by the customer.
When the diagnostic trouble code is in the 1. Reinvestigate the complaint.
When the diagnostic trouble code is in the 1. Reinvestigate the complaint.
memory When a complaint cannot be sufficiently detected or con- memory When a complaint cannot be sufficiently detected or con-
Accurately follow the specified diagnostic trouble code chart firmed, it is necessary to reperform diagnosis and Accurately follow the specified diagnostic trouble code chart firmed, it is necessary to reperform diagnosis and
to perform repair. recheck the complaint.As stated above in "When the to perform repair. recheck the complaint.As stated above in "When the
When there is no diagnostic trouble code problem is intermittent", it is possible that the complaint When there is no diagnostic trouble code problem is intermittent", it is possible that the complaint
Select the symptom from diagnosis for each symptom.Com- is either an intermittent problem or normal operation. Select the symptom from diagnosis for each symptom.Com- is either an intermittent problem or normal operation.
plete repair according to the diagnosis procedure.Inspection 2. Perform repair and confirm results. plete repair according to the diagnosis procedure.Inspection 2. Perform repair and confirm results.
can also be performed referencing function diagnosis. If the cause has been confirmed, perform repair.Confirm can also be performed referencing function diagnosis. If the cause has been confirmed, perform repair.Confirm
that the main unit operates correctly and confirm that the that the main unit operates correctly and confirm that the
When there is no applicable symptom symptoms have been corrected.This includes main unit When there is no applicable symptom symptoms have been corrected.This includes main unit
1. Investigate the complaint in detail. confirmation tests and other methods under the follow- 1. Investigate the complaint in detail. confirmation tests and other methods under the follow-
2. Create the diagnosis plan. ing conditions for confirming whether a complaint has 2. Create the diagnosis plan. ing conditions for confirming whether a complaint has
been resolved. been resolved.
3. Use wiring diagrams and operation principles. 3. Use wiring diagrams and operation principles.
In similar cases where the repair history can be obtained, • Perform a test under the status stated by the cus- In similar cases where the repair history can be obtained, • Perform a test under the status stated by the cus-
request technical support.This will combine technical knowl- tomer to check the complaint. request technical support.This will combine technical knowl- tomer to check the complaint.
edge with effective use of useful service information. • When a diagnostic trouble code is diagnosed, recre- edge with effective use of useful service information. • When a diagnostic trouble code is diagnosed, recre-
ate the status in which the diagnostic trouble code ate the status in which the diagnostic trouble code
When the problem is intermittent was set while checking the scan tool data and con- When the problem is intermittent was set while checking the scan tool data and con-
Problems that do not necessarily appear all of the time are firm whether repair has been done. Problems that do not necessarily appear all of the time are firm whether repair has been done.
referred to as intermittent.Follow the steps below to resolve referred to as intermittent.Follow the steps below to resolve
intermittent problems. intermittent problems.
1. Confirm the diagnostic trouble code information and 1. Confirm the diagnostic trouble code information and
data indication. data indication.
2. Evaluate symptoms and conditions stated by the cus- 2. Evaluate symptoms and conditions stated by the cus-
tomer. tomer.
3. Use a check sheet or another method to check circuits 3. Use a check sheet or another method to check circuits
or electrical system component parts. or electrical system component parts.

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Confirmation after Repair 1. Either the diagnostic trouble code and scan tool data Confirmation after Repair 1. Either the diagnostic trouble code and scan tool data
appearing during diagnosis or both should be reviewed appearing during diagnosis or both should be reviewed
Main unit repair confirmation and recorded. Main unit repair confirmation and recorded.
When the electrical control system has been repaired, it is 2. Delete the diagnostic trouble code. When the electrical control system has been repaired, it is 2. Delete the diagnostic trouble code.
necessary to confirm after main unit repair whether the repair necessary to confirm after main unit repair whether the repair
done was correct.If this confirmation is not done thoroughly, 3. Operate the main unit according to the scan tool data. done was correct.If this confirmation is not done thoroughly, 3. Operate the main unit according to the scan tool data.
messages may display again or operability problems may 4. Check the diagnostic trouble codes status information of messages may display again or operability problems may 4. Check the diagnostic trouble codes status information of
occur when the main unit is handed over to the customer.It is the diagnostic trouble codes specified when diagnosis occur when the main unit is handed over to the customer.It is the diagnostic trouble codes specified when diagnosis
especially necessary to recreate customer complaint condi- was performed until diagnostic tests related to those especially necessary to recreate customer complaint condi- was performed until diagnostic tests related to those
tions and confirm repair for intermittent problems. diagnostic trouble codes are performed by the control tions and confirm repair for intermittent problems. diagnostic trouble codes are performed by the control
unit. unit.
Main unit repair confirmation Implementation of these steps is very important when repair Main unit repair confirmation Implementation of these steps is very important when repair
Main unit repair confirmation is effective if a service support is confirmed through a service support check.Neglecting Main unit repair confirmation is effective if a service support is confirmed through a service support check.Neglecting
check is used.When repair is complete, the person diagnos- implementation of these steps sometimes makes otherwise check is used.When repair is complete, the person diagnos- implementation of these steps sometimes makes otherwise
ing the main unit should perform the following steps. unnecessary repair necessary. ing the main unit should perform the following steps. unnecessary repair necessary.
Final Confirmation Items List Final Confirmation Items List
No. Item Purpose Method No. Item Purpose Method
Checking diag- Checking after repair concern- Delete the previous diagnostic trouble code.Sufficiently warm up the Checking diag- Checking after repair concern- Delete the previous diagnostic trouble code.Sufficiently warm up the
1 nostic trouble ing a displayed diagnostic trou- engine through idling, and then raise the engine speed to the maxi- 1 nostic trouble ing a displayed diagnostic trou- engine through idling, and then raise the engine speed to the maxi-
codes ble code display mum in order to perform racing operation and achieve test conditions. codes ble code display mum in order to perform racing operation and achieve test conditions.
Confirmation of Confirmation of
This is done to confirm that Confirm that the idling speed after the engine has warmed up is con- This is done to confirm that Confirm that the idling speed after the engine has warmed up is con-
the idling speed the idling speed
2 idling control is operating nor- stant in no-load conditions.If a problem is detected, see the unstable 2 idling control is operating nor- stant in no-load conditions.If a problem is detected, see the unstable
after engine after engine
mally. idling during diagnosis for each symptom. mally. idling during diagnosis for each symptom.
warm up warm up
Confirm whether engine control Confirm whether engine control
Confirmation of Monitor the scan tools data list and use the representative values list Confirmation of Monitor the scan tools data list and use the representative values list
and communication are normal and communication are normal
3 the scan tools to check. 3 the scan tools to check.
or abnormal during standard or abnormal during standard
data list Confirm the scan tools data list representative values. data list Confirm the scan tools data list representative values.
conditions. conditions.
Confirmation of This is done to confirm that start Confirm that the cranking time is 5 sec. or less and the engine speed Confirmation of This is done to confirm that start Confirm that the cranking time is 5 sec. or less and the engine speed
4 4
restartability control is operating normally. stabilizes after the engine has been started during restarting. restartability control is operating normally. stabilizes after the engine has been started during restarting.
When a electrical signal trans- When a electrical signal trans-
Confirmation of Confirm that the engine idling speed changes when switching Confirmation of Confirm that the engine idling speed changes when switching
mission part such as a trans- mission part such as a trans-
high-powered between "ON" and "OFF" is performed with an electrical signal trans- high-powered between "ON" and "OFF" is performed with an electrical signal trans-
ceiver has been mounted, ceiver has been mounted,
5 electrical signal mission part such as a transceiver.If a problem is discovered, inform 5 electrical signal mission part such as a transceiver.If a problem is discovered, inform
confirm that there is no electro- confirm that there is no electro-
transmission the customer of the necessity of changing the installation location and transmission the customer of the necessity of changing the installation location and
magnetic interference being magnetic interference being
device output of the electrical signal transmission device. device output of the electrical signal transmission device.
emitted as a result. emitted as a result.

Supplemental information for confirmation of high-powered Caution: Supplemental information for confirmation of high-powered Caution:
electrical signal transmission device: If a problem is discov- When repair confirmation is done through a service sup- electrical signal transmission device: If a problem is discov- When repair confirmation is done through a service sup-
ered with this item, contact the customer as necessary con- port check, following the steps below.If these steps are ered with this item, contact the customer as necessary con- port check, following the steps below.If these steps are
cerning the following items. not followed, unnecessary repair may be performed. cerning the following items. not followed, unnecessary repair may be performed.
• For parts that are installed after shipping, follow the indi- • Review and record the scan tool data related to diag- • For parts that are installed after shipping, follow the indi- • Review and record the scan tool data related to diag-
vidual installation procedures to securely install each nostic trouble code for which diagnosis was per- vidual installation procedures to securely install each nostic trouble code for which diagnosis was per-
part. formed. part. formed.
• Antenna codes should be installed at a location at least • Clear the diagnostic trouble code. • Antenna codes should be installed at a location at least • Clear the diagnostic trouble code.
20 cm (7.8 in) away from main unit electrical system • Operate the main unit while checking the related 20 cm (7.8 in) away from main unit electrical system • Operate the main unit while checking the related
components such as the control unit and sensors. scan tool data. components such as the control unit and sensors. scan tool data.
• Do not mix antenna cords with other wiring. Also, place • Do not mix antenna cords with other wiring. Also, place
antenna cords and other wiring as far away from each Diagnostic Trouble Code Deletion Method antenna cords and other wiring as far away from each Diagnostic Trouble Code Deletion Method
other as possible. other as possible.
• For parts that are installed after shipping, follow the indi-
Diagnostic trouble code deletion • For parts that are installed after shipping, follow the indi-
Diagnostic trouble code deletion
vidual installation procedures to securely install each When an abnormality has occurred in the system and a diag- vidual installation procedures to securely install each When an abnormality has occurred in the system and a diag-
part. nostic trouble code is recorded in the engine control module part. nostic trouble code is recorded in the engine control module
(ECM), the diagnostic trouble code will not be deleted from (ECM), the diagnostic trouble code will not be deleted from
• Do not install high-output movement communication • Do not install high-output movement communication
memory even if the location of the trouble is repaired. Forced memory even if the location of the trouble is repaired. Forced
devices. devices.
deletion is done according to separate procedures. deletion is done according to separate procedures.
For information on diagnostic trouble codes stored in com- For information on diagnostic trouble codes stored in com-
puter A of the main unit, see the Service Support items in the puter A of the main unit, see the Service Support items in the
main unit service text. main unit service text.

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Injector Inspection Methods Using A Thermogun Injector Inspection Methods Using A Thermogun
Common rail-type fuel injection device injectors are located inside the head cover, and inspection (removal and installation of Common rail-type fuel injection device injectors are located inside the head cover, and inspection (removal and installation of
couplers, outside injection from cylinder) cannot be performed.An inspection method for mechanical problems (spray deficien- couplers, outside injection from cylinder) cannot be performed.An inspection method for mechanical problems (spray deficien-
cies, clogging, seizing) for which a diagnostic trouble code does not appear is necessary. cies, clogging, seizing) for which a diagnostic trouble code does not appear is necessary.
Judgment through temperature measurement Judgment through temperature measurement
For engines in which combustion conditions are normal, the temperature of each cylinder will ordinarily increase. For engines in which combustion conditions are normal, the temperature of each cylinder will ordinarily increase.
However, for cylinders in which there is trouble and combustion conditions are poor, it is difficult for the temperature to increase. However, for cylinders in which there is trouble and combustion conditions are poor, it is difficult for the temperature to increase.
Use these characteristics and observe the temperature change in each cylinder to judge whether there are cylinder problems. Use these characteristics and observe the temperature change in each cylinder to judge whether there are cylinder problems.

«Difference in temperature change by state of combustion» «Difference in temperature change by state of combustion»

Complete combustion Complete combustion


Temperature

Temperature
Incomplete combustion Incomplete combustion

Hours Hours
Cylinders with low temperature have poor status of combustion. Cylinders with low temperature have poor status of combustion.
Therefore, you can judge that there has been some kind of trouble. 655# Therefore, you can judge that there has been some kind of trouble. 655#

The cause of the problem is often a defect (spray deficiencies, clogging, seizing) with the injector itself. The cause of the problem is often a defect (spray deficiencies, clogging, seizing) with the injector itself.
Also investigate other causes and thoroughly perform trouble diagnosis before deciding what the problem is. Also investigate other causes and thoroughly perform trouble diagnosis before deciding what the problem is.
Thermogun Thermogun
A thermogun is a infrared thermometer capable of noncontact temperature measurement. A thermogun is a infrared thermometer capable of noncontact temperature measurement.
As a maintenance tool, this is sold as a thermogun and infrared thermometer. As a maintenance tool, this is sold as a thermogun and infrared thermometer.
• Ideal for measuring temperatures from 0 °C to 500 °C. • Ideal for measuring temperatures from 0 °C to 500 °C.
• Includes laser pointer • Includes laser pointer
• Includes spot measurement function (convergence ratio of about 10:1) • Includes spot measurement function (convergence ratio of about 10:1)

TSSA0004 TSSA0004

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Measurement preparation Measurement preparation
Prepare the thermogun. Prepare the thermogun.
Open the engine housing and check the exhaust manifold Open the engine housing and check the exhaust manifold
base measurement location. base measurement location.
• Confirm that the measurement distance and angle of the thermogun are being kept constant. • Confirm that the measurement distance and angle of the thermogun are being kept constant.
• This will cause measurement errors with each cylinder, so practice this when it will have no effect on operation. • This will cause measurement errors with each cylinder, so practice this when it will have no effect on operation.
• The nearer the measurement distance is to about 30 cm, the more stable the measurement value will be. • The nearer the measurement distance is to about 30 cm, the more stable the measurement value will be.
• If measurement data is recorded, it can also be used in customer explanations. • If measurement data is recorded, it can also be used in customer explanations.

Measurement procedure Measurement procedure


Start measurement with the exhaust pipe temperature at 100 °C or less. Start measurement with the exhaust pipe temperature at 100 °C or less.
1. Measure the initial status temperatures 1. Measure the initial status temperatures
................................................ Record the temperatures ................................................ Record the temperatures
2. Start the engine.Maximum speed/2 pump relief 2. Start the engine.Maximum speed/2 pump relief
3. Implement temperature measurement for cylinders 1 through 4 at a pace of about 30 sec. for 1 measurement 3. Implement temperature measurement for cylinders 1 through 4 at a pace of about 30 sec. for 1 measurement
................................................ Record the temperatures ................................................ Record the temperatures
4. Repeat step 2 about 6 to 7 times. 4. Repeat step 2 about 6 to 7 times.
5. When the temperatures get to about 400 °C, confirm that temperature increases are less sensitive. 5. When the temperatures get to about 400 °C, confirm that temperature increases are less sensitive.
6. After completing measurement, stop the engine after idling. 6. After completing measurement, stop the engine after idling.
7. Narrow down the problem cylinder from the measurement values. 7. Narrow down the problem cylinder from the measurement values.
• After 5 min. pass, it will become more difficult to determine the problem cylinder. • After 5 min. pass, it will become more difficult to determine the problem cylinder.
• To perform measurement again, it is necessary to let the engine cool (below 100 °C). • To perform measurement again, it is necessary to let the engine cool (below 100 °C).

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Judgment criteria Judgment criteria
Rather than looking for an absolute value, judgment is done through comparing the temperature changes of each cylinder and Rather than looking for an absolute value, judgment is done through comparing the temperature changes of each cylinder and
finding the cylinder with a relatively low temperature change. finding the cylinder with a relatively low temperature change.
The actual measurement values below are listed as reference data. The actual measurement values below are listed as reference data.
Measurement temperatures vary depending on the measurement conditions, so see the data below as reference data for under- Measurement temperatures vary depending on the measurement conditions, so see the data below as reference data for under-
standing general tendencies. standing general tendencies.
In the typical measurement example, the following 3 measurements are listed. In the typical measurement example, the following 3 measurements are listed.
1. Data during normal operation 1. Data during normal operation
2. When one of the cylinders on the end (number 1 or 4) is in an incomplete combustion stage 2. When one of the cylinders on the end (number 1 or 4) is in an incomplete combustion stage
3. When a middle cylinder (number 3) is in an incomplete combustion state 3. When a middle cylinder (number 3) is in an incomplete combustion state
* Weather when reference data was obtained (outside temperature: 28 °C/weather: clear) * Weather when reference data was obtained (outside temperature: 28 °C/weather: clear)
Work precautions Work precautions
• Confirm that there are no people around the machine and perform work in a safe manner. • Confirm that there are no people around the machine and perform work in a safe manner.
• When measuring, be aware of the engine temperature. • When measuring, be aware of the engine temperature.
• Make sure to apply the swing lock. • Make sure to apply the swing lock.
[Tip] [Tip]
During normal operation before the vehicle is delivered, measure and record the manifold temperature of all cylinders and keep During normal operation before the vehicle is delivered, measure and record the manifold temperature of all cylinders and keep
this as judgment data for when a problem occurs. this as judgment data for when a problem occurs.

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Problem injector selection method Problem injector selection method
The comparison data below is test data for reference use. The comparison data below is test data for reference use.

Caution: Caution:
Be aware that measurement values that differ from the test values may appear due to the actual test environment and Be aware that measurement values that differ from the test values may appear due to the actual test environment and
main unit condition. main unit condition.

[During normal operation] [During normal operation]

During normal operation, the same temperature fluctuation tendencies are present in all of the cylinders. During normal operation, the same temperature fluctuation tendencies are present in all of the cylinders.

°C °C
Test time #1 #2 #3 #4 Test time #1 #2 #3 #4
0 21 21 21 21 0 21 21 21 21
40 51 55 55 55 40 51 55 55 55
1:10 170 169 174 199 1:10 170 169 174 199
1:40 265 256 250 272 1:40 265 256 250 272
2:20 304 324 302 334 2:20 304 324 302 334
2:40 328 342 328 358 2:40 328 342 328 358

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[When the No.1 cylinder injection is stopped] [When the No.1 cylinder injection is stopped]

A marked temperature difference can be seen in comparison with the cylinders that are performing normal injection. A marked temperature difference can be seen in comparison with the cylinders that are performing normal injection.

°C °C
Test time #1 #2 #3 #4 Test time #1 #2 #3 #4
0 56 60 66 65 0 56 60 66 65
35 57 135 193 193 35 57 135 193 193
1:00 61 165 246 255 1:00 61 165 246 255
1:25 66 187 288 312 1:25 66 187 288 312
2:00 74 208 305 341 2:00 74 208 305 341
2:30 77 217 332 345 2:30 77 217 332 345
3:05 80 221 346 367 3:05 80 221 346 367

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[When the No.3 cylinder injection is stopped] [When the No.3 cylinder injection is stopped]

The cylinder fluctuates at a lower temperature range than the normally operating cylinders. The cylinder fluctuates at a lower temperature range than the normally operating cylinders.

°C °C
Test time #1 #2 #3 #4 Test time #1 #2 #3 #4
0 81 91 105 101 0 81 91 105 101
30 127 180 128 245 30 127 180 128 245
1:10 202 297 145 275 1:10 202 297 145 275
1:40 233 332 206 311 1:40 233 332 206 311
2:20 263 367 206 342 2:20 263 367 206 342
2:50 294 365 253 354 2:50 294 365 253 354
3:25 297 398 253 369 3:25 297 398 253 369

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[When the No.4 cylinder injection is stopped] [When the No.4 cylinder injection is stopped]

A marked temperature difference can be seen in comparison with the cylinders that are performing normal injection. A marked temperature difference can be seen in comparison with the cylinders that are performing normal injection.

°C °C
Test time #1 #2 #3 #4 Test time #1 #2 #3 #4
0 101 100 85 56 0 101 100 85 56
40 136 159 130 60 40 136 159 130 60
1:10 224 241 170 65 1:10 224 241 170 65
1:40 252 295 200 70 1:40 252 295 200 70
2:20 320 333 243 74 2:20 320 333 243 74
2:40 331 340 255 80 2:40 331 340 255 80
3:25 380 398 260 95 3:25 380 398 260 95

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Examples of symptoms in which injector Examples of symptoms in which injector
inspection is necessary inspection is necessary
Symptoms for which an injector operation problem is some- Symptoms for which an injector operation problem is some-
times the cause include lack of engine power, unstable rota- times the cause include lack of engine power, unstable rota-
tion, and abnormal engine noises. tion, and abnormal engine noises.
However, because these are mechanical problems (spray However, because these are mechanical problems (spray
deficiencies, clogging, seizing), a diagnostic trouble code deficiencies, clogging, seizing), a diagnostic trouble code
does not display. does not display.
Temperature measurement using a thermogun is an effective Temperature measurement using a thermogun is an effective
trouble diagnosis method. trouble diagnosis method.
Symptom examples that appear in this manual for which Symptom examples that appear in this manual for which
injector inspection is necessary are listed below. injector inspection is necessary are listed below.
Problem symptoms Problem symptoms
• Engine starting defects • Engine starting defects
• Engine hunting, rough idling • Engine hunting, rough idling
• Engine output deficiencies • Engine output deficiencies
• Great deal of white smoke in exhaust gas • Great deal of white smoke in exhaust gas
• High fuel consumption • High fuel consumption
Sorting Methods Using Noncontact Sorting Methods Using Noncontact
Infrared Thermometer Infrared Thermometer
The 3 injector sorting methods are shown below. The sorting The 3 injector sorting methods are shown below. The sorting
method will vary depending on the difficulty of judgment method will vary depending on the difficulty of judgment
which will vary according to the existence of certain tools and which will vary according to the existence of certain tools and
the model, so see "Diferrence by each machine manufac- the model, so see "Diferrence by each machine manufac-
turer". turer".
Sorting methods Sorting methods
1. Judgement method using injector balance test per- 1. Judgement method using injector balance test per-
formed with trouble diagnosis tool using Tech-II KW, formed with trouble diagnosis tool using Tech-II KW,
CAN communication. CAN communication.
• See "Injector balance test, Tech2, How to use trou- • See "Injector balance test, Tech2, How to use trou-
ble diagnosis-related tool" for the balance test ble diagnosis-related tool" for the balance test
method. method.
2. Judgment method using injector balance test in which 2. Judgment method using injector balance test in which
communication with the ECM is not performed and an communication with the ECM is not performed and an
injector checker is used to disconnect the injector power injector checker is used to disconnect the injector power
line for a short period.ECM line for a short period.ECM
• See "How to use injector checker, How to inspect • See "How to use injector checker, How to inspect
injector". injector".
3. Judgment method in which measurement and compari- 3. Judgment method in which measurement and compari-
son of exhaust gas temperature increase tendencies is son of exhaust gas temperature increase tendencies is
performed using a noncontact infrared thermometer. performed using a noncontact infrared thermometer.
When there are no trouble diagnosis tools and only injector When there are no trouble diagnosis tools and only injector
checker methods are used, proficiency in judgment may be checker methods are used, proficiency in judgment may be
required depending on the main unit type.If judgment is diffi- required depending on the main unit type.If judgment is diffi-
cult, the judgment method consisting of comparing exhaust cult, the judgment method consisting of comparing exhaust
pipe temperatures using a noncontact infrared thermometer pipe temperatures using a noncontact infrared thermometer
is recommended. is recommended.
Measurement method Measurement method
Use an infrared thermometer that is capable of measuring Use an infrared thermometer that is capable of measuring
temperatures of 500 °C and perform continuous measure- temperatures of 500 °C and perform continuous measure-
ment at the rated point in which the engine condition is stable ment at the rated point in which the engine condition is stable
(For shovels, this is the point from 2 pumps relief.) and mea- (For shovels, this is the point from 2 pumps relief.) and mea-
surement can be done. surement can be done.
If the exhaust pipe temperature of one of the cylinders is If the exhaust pipe temperature of one of the cylinders is
markedly lower than the others when each of the cylinder markedly lower than the others when each of the cylinder
temperatures is measured and compared during a measure- temperatures is measured and compared during a measure-
ment period 3 to 5 min. after the engine has stabilized, it is ment period 3 to 5 min. after the engine has stabilized, it is
judged that there is a problem with this cylinder. judged that there is a problem with this cylinder.

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Breaker Box Inspection Procedure Important: Breaker Box Inspection Procedure Important:
The breaker box is a tool by which inspection of connector When inspecting and measuring ECM voltage and con- The breaker box is a tool by which inspection of connector When inspecting and measuring ECM voltage and con-
pin, harness disconnections, shorts or the like among the duction, use a breaker box and an adapter harness that is pin, harness disconnections, shorts or the like among the duction, use a breaker box and an adapter harness that is
ECM, each sensor, and actuator, for which inspection was suitable for the main unit to be inspected. ECM, each sensor, and actuator, for which inspection was suitable for the main unit to be inspected.
normally difficult, can be easily done.The voltage and conduc- • Due to the possibility that the ECM could be dam- normally difficult, can be easily done.The voltage and conduc- • Due to the possibility that the ECM could be dam-
tion that is being applied to the ECM pins moves through the aged, confirm pin locations before work when per- tion that is being applied to the ECM pins moves through the aged, confirm pin locations before work when per-
breaker box and can be measured using a digital multimeter forming inspection and measurement with the ECM. breaker box and can be measured using a digital multimeter forming inspection and measurement with the ECM.
(5-8840-2691-0).Also, by using scan tools along with the mul- (5-8840-2691-0).Also, by using scan tools along with the mul-
timeter, even more reliable maintenance inspection can be Note: timeter, even more reliable maintenance inspection can be Note:
performed. The ECM pin number and breaker box pin number within the performed. The ECM pin number and breaker box pin number within the
diagnosis steps should match. diagnosis steps should match.

1 2 1 2
A A

B B

C C

TSWG0049 TSWG0049

Name Name
1. Breaker box 2. Adaptor harness 1. Breaker box 2. Adaptor harness

Breaker box connection method 1. Disconnect the ECM connectors from the ECM. Breaker box connection method 1. Disconnect the ECM connectors from the ECM.
Caution: 2. Connect the adapter harness connectors to the ECM. Caution: 2. Connect the adapter harness connectors to the ECM.
Turn the key switch OFF before removing and installing 3. Connect the ECM connectors to the adapter harness. Turn the key switch OFF before removing and installing 3. Connect the ECM connectors to the adapter harness.
connectors. connectors.
4. Connect the adapter harness to the breaker box. 4. Connect the adapter harness to the breaker box.

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4 4

2 2

3 3
1 1

TSWG0050 TSWG0050

Name Name
1. Breaker box 3. ECM 1. Breaker box 3. ECM
2. Adaptor harness 4. To main unit side harness 2. Adaptor harness 4. To main unit side harness

Caution: Breaker box use example Caution: Breaker box use example
Be aware of the following points when connecting the Be aware of the following points when connecting the
1. Voltage inspection and measurement 1. Voltage inspection and measurement
adapter harness to the breaker box.Making a wrong con- adapter harness to the breaker box.Making a wrong con-
nection can cause damage to the ECM. • Coolant temperature sensor nection can cause damage to the ECM. • Coolant temperature sensor
• Connectors with the same connector number on the • Suction air temperature sensor, etc. • Connectors with the same connector number on the • Suction air temperature sensor, etc.
adapter harness side and breaker box should be adapter harness side and breaker box should be
connected. connected.
• When connecting connectors, align the notches on • When connecting connectors, align the notches on
the connectors and the breaker box. 3 the connectors and the breaker box. 3

2 2
1 1

2 2

1 1

TSWG0052 TSWG0052
1 Name 1 Name
2 2
1. Breaker box 1. Breaker box
2. ECM 2. ECM
Name 3. Digital multi-meter Name 3. Digital multi-meter
1. Connector number (adapter harness) 1. Connector number (adapter harness)
2. Connector number (breaker box) 2. Connector number (breaker box)

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2. Resistance inspection and measurement 2. Resistance inspection and measurement
• Crankshaft position sensor • Crankshaft position sensor
• Camshaft position sensor • Camshaft position sensor
• SCV, etc. • SCV, etc.

3 3

2 2

1 1

TSWG0053 TSWG0053
Name Name
1. Breaker box 1. Breaker box
2. ECM 2. ECM
3. Digital multi-meter 3. Digital multi-meter

3. Inspection and measurement with oscilloscope 3. Inspection and measurement with oscilloscope
• Crankshaft position (CKP) sensor signal • Crankshaft position (CKP) sensor signal
• Camshaft position (CMP) sensor signal, etc. • Camshaft position (CMP) sensor signal, etc.

3 3

2 2

1 1

TSWG0054 TSWG0054
Name Name
1. Breaker box 1. Breaker box
2. ECM 2. ECM
3. Oscilloscope 3. Oscilloscope

Caution: Caution:
The ECM and sensors can be damaged if measurement The ECM and sensors can be damaged if measurement
cable interference or a measurement terminal mistake cable interference or a measurement terminal mistake
occurs on the breaker box during inspection and mea- occurs on the breaker box during inspection and mea-
surement.Use sufficient caution when performing work. surement.Use sufficient caution when performing work.

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Engine Control System Engine Control System


Engine Control (common rail) System Functions and Operation Explanation Engine Control (common rail) System Functions and Operation Explanation
Overview and further information of engine • EGR (exhaust gas recirculation) Overview and further information of engine • EGR (exhaust gas recirculation)
control system • Idling control control system • Idling control
The engine control system is an electronic control system for Also, the engine control system also has the following system The engine control system is an electronic control system for Also, the engine control system also has the following system
engine control in order to always maintain optimum combus- control functions apart from engine control. engine control in order to always maintain optimum combus- control functions apart from engine control.
tion status in accordance with the operation conditions. It con- • Engine rotation signal output tion status in accordance with the operation conditions. It con- • Engine rotation signal output
sists of the following. • Self-diagnosis function sists of the following. • Self-diagnosis function
• Electronic control fuel injection system (common rail • CAN (Controller area network) communication (SAE • Electronic control fuel injection system (common rail • CAN (Controller area network) communication (SAE
type) J1939/21, SAE J1939/11) type) J1939/21, SAE J1939/11)
System control summary diagram System control summary diagram

Engine control module (ECM) Engine control module (ECM)

CAN communication Computer A CAN communication Computer A


Basic fuel injection amount Basic fuel injection amount
Boost pressure sensor input Boost pressure sensor input
CKP sensor input CKP sensor input
CMP sensor input CMP sensor input

Correction Correction
Engine coolant temperature correction Engine coolant temperature correction
Barometric Pressure correction Barometric Pressure correction
Fuel temperature boost pressure correction Fuel temperature boost pressure correction
Correction between cylinders Correction between cylinders
Q-key correction Q-key correction
QR correction QR correction

Correction Correction

SCV opening SCV opening


time determination Injector coil energizing time time determination Injector coil energizing time
Timing determination Timing determination

Common rail pressure sensor Common rail pressure sensor

Common rail Common rail

Injector coil Injector coil

SCV SCV

Injector Injector

Supply pump Supply pump

Fuel tank Fuel tank

TSHK0001 TSHK0001

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Fuel injection correction Control for overheating Fuel injection correction Control for overheating
The ECM calculates the basic injection quantity from signals The ECM, in order to protect the engine, will start control of The ECM calculates the basic injection quantity from signals The ECM, in order to protect the engine, will start control of
from the boost pressure sensor, CKP sensor, and CMP sen- the fuel flow if the engine coolant temperature exceeds from the boost pressure sensor, CKP sensor, and CMP sen- the fuel flow if the engine coolant temperature exceeds
sor.It uses conditions such as the common rail pressure and 100 °C.If the engine coolant temperature rises further, the sor.It uses conditions such as the common rail pressure and 100 °C.If the engine coolant temperature rises further, the
engine coolant temperature at the time to control the SCV fuel flow is further restricted.Near 120 °C, the fuel flow will be engine coolant temperature at the time to control the SCV fuel flow is further restricted.Near 120 °C, the fuel flow will be
opening and closing interval and the injector electrified time restricted to a constant level. opening and closing interval and the injector electrified time restricted to a constant level.
and it makes corrections for the optimum injection timing and An warning will also be emitted from the system by computer and it makes corrections for the optimum injection timing and An warning will also be emitted from the system by computer
injection quantitys. A from 105 °C.Along with the warning, the fuel flow will be injection quantitys. A from 105 °C.Along with the warning, the fuel flow will be
gradually restricted, and the engine will be stopped even if gradually restricted, and the engine will be stopped even if
Starting Q correction the temperature rises.
Starting Q correction the temperature rises.
The ECM corrects the starting Q during engine starting when The ECM corrects the starting Q during engine starting when
the engine rotation is below the starting Q threshold. the engine rotation is below the starting Q threshold.
Also, the ECM does not recognize engine rotation during Also, the ECM does not recognize engine rotation during
rotation that is at or below the system recognition level, so it rotation that is at or below the system recognition level, so it
cannot correct starting Q or start the engine at this time. cannot correct starting Q or start the engine at this time.

100 (212 ) 100 (212 )


100 % 100 %
Engine speed (min-1)

Engine speed (min-1)


Fuel flow

Fuel flow
Starting Q correction Threshold engine speed Starting Q correction Threshold engine speed
(248 ) (248 )
550 550
20 % 20 %

(221 ) (221 )
Water temperature Water temperature

Minimum Starting engine speed Minimum Starting engine speed


60 TSWG0169 60 TSWG0169

30 30
System recognition engine speed System recognition engine speed

TSWG0175 TSWG0175

High altitude correction High altitude correction


The ECM calculates the current altitude from the atmospheric The ECM calculates the current altitude from the atmospheric
pressure sensor signals. pressure sensor signals.
Corrections to achieve the optimum fuel flow are made from Corrections to achieve the optimum fuel flow are made from
the altitude conditions at this time. the altitude conditions at this time.
Fuel flow limit (mm3 /st)

Fuel flow limit (mm3 /st)

Barometric pressure (kPa) Barometric pressure (kPa)


highland highland

TSWG0173 TSWG0173

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Input/output chart Input/output chart

Communication Communication
Injection control output Injection control output
• Speed signal • Speed signal
• SCV (Suction control valve) • SCV (Suction control valve)
• Tech 2 signal • Tech 2 signal
• TWV (Injector) 4H : 1~4 • TWV (Injector) 4H : 1~4
• CAN (Computer) • CAN (Computer)

Actuator control output Actuator control output


• EGR DC motor • EGR DC motor

ECM ECM

Relay, control output Relay, control output


Sensor input • Glow relay Sensor input • Glow relay
• CKP sensor • Starter cut relay • CKP sensor • Starter cut relay
• CMP sensor • CMP sensor
• Water temperature sensor • Water temperature sensor
• Fuel temperature sensor • Fuel temperature sensor
• Barometric pressure sensor • Barometric pressure sensor
• Common rail pressure sensor • Common rail pressure sensor
• Boost pressure sensor • Boost pressure sensor
• Oil pressure sensor • Oil pressure sensor
• Boost temperature sensor • Boost temperature sensor
• Intake air temperature sensor • Intake air temperature sensor
• EGR position sensor • EGR position sensor

TSHK0002 TSHK0002

Electronic control fuel injection system Injection quantity control Electronic control fuel injection system Injection quantity control
(common rail type) To provide the optimum injection quantity, the ECM controls (common rail type) To provide the optimum injection quantity, the ECM controls
This is a system in which the engine speed, engine load, and the injectors based mainly on engine speed signals and the This is a system in which the engine speed, engine load, and the injectors based mainly on engine speed signals and the
other information (signals from many sensors) are acquired speed indicated by main unit computer A. other information (signals from many sensors) are acquired speed indicated by main unit computer A.
by the engine control module (ECM) and, based on that infor- by the engine control module (ECM) and, based on that infor-
mation, the ECM sends electrical signals to the supply pump, mation, the ECM sends electrical signals to the supply pump,
injectors, or the like to appropriately control the fuel injection injectors, or the like to appropriately control the fuel injection
quantity and timing of each cylinder. quantity and timing of each cylinder.

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Computer A Computer A
Basic Basic
Fuel Injection Fuel Injection
Quantity Quantity
Final Fuel Injection Final Fuel Injection
Engine Fuel Injection Quantity Injector ON Time Engine Fuel Injection Quantity Injector ON Time
Reduction Rate Reduction Rate
Speed Quantity Correction Determination Speed Quantity Correction Determination
Maximum Maximum
Fuel Injection Fuel Injection
Quantity Quantity

࡮Boost Press. ࡮Boost Press.


࡮Coolant Temp. ࡮Coolant Temp.
࡮Barometric Press. ࡮Barometric Press.

TSHK0172E TSHK0172E

Maximum fuel injection quantity Injection timing control Maximum fuel injection quantity Injection timing control
The maximum fuel injection quantity is calculated from adjust- Instead of a timer function, the injectors are controlled prima- The maximum fuel injection quantity is calculated from adjust- Instead of a timer function, the injectors are controlled prima-
ment of the starting injection quantity according to coolant rily by calculating the appropriate fuel injection timing from the ment of the starting injection quantity according to coolant rily by calculating the appropriate fuel injection timing from the
temperature, restriction of the maximum injection quantity engine speed, injection quantity, or the like. temperature, restriction of the maximum injection quantity engine speed, injection quantity, or the like.
according to the boost pressure, and control of the high-alti- according to the boost pressure, and control of the high-alti-
tude injection quantity according to atmospheric pressure. Injection ratio control tude injection quantity according to atmospheric pressure. Injection ratio control
In order to improve the combustion in the cylinder, at first only In order to improve the combustion in the cylinder, at first only
Injection pressure control a small amount of fuel is injected (pre-injection), the fuel is Injection pressure control a small amount of fuel is injected (pre-injection), the fuel is
The injection pressure is controlled by controlling the fuel ignited, then once the fuel has ignited, a second injection The injection pressure is controlled by controlling the fuel ignited, then once the fuel has ignited, a second injection
pressure in the common rail.The appropriate pressure in the (main injection) is carried out.This injection timing and quan- pressure in the common rail.The appropriate pressure in the (main injection) is carried out.This injection timing and quan-
common rail is calculated from the engine speed and fuel tity control is performed through controlling the injectors. common rail is calculated from the engine speed and fuel tity control is performed through controlling the injectors.
injection quantity, and control is performed by discharging the injection quantity, and control is performed by discharging the
appropriate fuel amount through supply pump control and appropriate fuel amount through supply pump control and
pressure feeding this fuel to the common rail. pressure feeding this fuel to the common rail.

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4023-39 4023-39
System summary diagram System summary diagram

Common rail Common rail


Pressure Pressure
pressure sensor Common rail pressure sensor Common rail
limiter limiter

Electromagnetic Fuel filter Electromagnetic Fuel filter


pump pump

Supply pump Supply pump

Pre filter Pre filter

Injector Injector

Fuel tank 㧱㧯㧹 Fuel tank 㧱㧯㧹

Each sensor Each sensor


Accelerator, Boost pressure, Accelerator, Boost pressure,
Engine coolant temperature, etc. Engine coolant temperature, etc.
CMP sensor CKP sensor CMP sensor CKP sensor

TSJJ0102E TSJJ0102E

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4023-40 4023-40
Fuel system Fuel system
Fuel is supplied to the supply pump from the fuel tank and Fuel is supplied to the supply pump from the fuel tank and
then supplied to the common rail after a pressure boost by then supplied to the common rail after a pressure boost by
the pump.The amount of fuel supplied to the common rail is the pump.The amount of fuel supplied to the common rail is
controlled by controlling the suction control valve (SCV) controlled by controlling the suction control valve (SCV)
through the signals from the ECM at this time. through the signals from the ECM at this time.

2 2

3 3
1 1

6 6

4 4
5 5

8 8
7 7

TSJJ0103 TSJJ0103

Name Name
1. Common rail 5. Fuel tank 1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump 2. Fuel filter 6. Supply pump
3. Charge fuel pump 7. Injector 3. Charge fuel pump 7. Injector
4. Pre-filter 8. Fuel cooler 4. Pre-filter 8. Fuel cooler

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Fuel system air bleeding Fuel system air bleeding

1 0   1 0  
( (

56

56
1(

1(
*1 *1

Electromagnetic Fuel filter Electromagnetic Fuel filter


pump pump
Pre Fuel filter Pre Fuel filter

Supply pump Supply pump

Fuel tank Fuel tank


TSHK0178E TSHK0178E

1. Place a suitable drip pan under the air bleed plug. EGR (exhaust gas recirculation) 1. Place a suitable drip pan under the air bleed plug. EGR (exhaust gas recirculation)
2. Turn the key switch ON to operate the charge fuel pump. EGR system is an abbreviation for "exhaust gas recirculation" 2. Turn the key switch ON to operate the charge fuel pump. EGR system is an abbreviation for "exhaust gas recirculation"
3. Sufficiently loosen the fuel filter air bleed plug and oper- system. The EGR system recirculates part of the exhaust gas 3. Sufficiently loosen the fuel filter air bleed plug and oper- system. The EGR system recirculates part of the exhaust gas
ate the priming pump at least 20 times until fuel begins in the intake manifold and mixes inactive gases with the suc- ate the priming pump at least 20 times until fuel begins in the intake manifold and mixes inactive gases with the suc-
to spill out from near the plug. tion air to reduce the combustion temperature and suppress to spill out from near the plug. tion air to reduce the combustion temperature and suppress
the generation of nitrogen oxides (NOx). the generation of nitrogen oxides (NOx).
4. Tighten the plug and operate the priming pump at least 4. Tighten the plug and operate the priming pump at least
The EGR quantity is controlled by the operation (opening and The EGR quantity is controlled by the operation (opening and
10 times until fuel is fully filled. 10 times until fuel is fully filled.
closing) of the EGR valve, which is installed between the closing) of the EGR valve, which is installed between the
After waiting about 1 min., loosen the plug and bleed the exhaust manifold and the intake manifold.The ERG quantity After waiting about 1 min., loosen the plug and bleed the exhaust manifold and the intake manifold.The ERG quantity
air out of the fuel filter.(Repeat this at least 3 times until air out of the fuel filter.(Repeat this at least 3 times until
is determined from the engine speed and engine load ratio is determined from the engine speed and engine load ratio
air no longer comes out from the plug.) air no longer comes out from the plug.)
(fuel injection quantity), the EGR valve is operated, and the (fuel injection quantity), the EGR valve is operated, and the
5. Securely fasten each plug and wipe away any spilled EGR amount is controlled. 5. Securely fasten each plug and wipe away any spilled EGR amount is controlled.
fuel around the plugs.Operate the priming pump until A cooling system (EGR cooler) is installed in the EGR gas fuel around the plugs.Operate the priming pump until A cooling system (EGR cooler) is installed in the EGR gas
fuel is fully filled and fuel has reached the engine. (10 - path to cool the high-temperature EGR gas with this EGR fuel is fully filled and fuel has reached the engine. (10 - path to cool the high-temperature EGR gas with this EGR
15 times) cooler. This cooled EGR gas is mixed with new air intake to 15 times) cooler. This cooled EGR gas is mixed with new air intake to
make the combustion temperature lower than with normal make the combustion temperature lower than with normal
EGR, which contributes to the reduction of NOx.(Cooled EGR, which contributes to the reduction of NOx.(Cooled
EGR) EGR)

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EGR control EGR control
The ECM operates the motor according to engine status fac- The ECM operates the motor according to engine status fac-
tors such as speed and load and it controls the EGR valve lift tors such as speed and load and it controls the EGR valve lift
amount.The valve lift amount is detected by the EGR sensor. amount.The valve lift amount is detected by the EGR sensor.
The sections shown in the darker color in the diagram have The sections shown in the darker color in the diagram have
larger valve lift amounts. The darkest color indicates a lift larger valve lift amounts. The darkest color indicates a lift
amount near 50 %. amount near 50 %.

Accelerator position

Accelerator position
No idle EGR No idle EGR

Engine speed Engine speed

TSJJ0159E TSJJ0159E

EGR system summary diagram EGR system summary diagram

Outlet port of coolant Inlet port of coolant Outlet port of coolant Inlet port of coolant
EGR cooler EGR cooler

EGR valve EGR valve

EGR valve position sensor EGR valve position sensor


Exhaust Exhaust

Boost temperature Boost temperature


sensor sensor
Engine control module Engine control module
(ECM) (ECM)
Boost pressure sensor Boost pressure sensor

Intake air Intake air


Intake air temperature sensor Intake air temperature sensor

Engine speed Engine speed

ECT sensor ECT sensor

Engine load Engine load

TSJJ0153E TSJJ0153E

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Engine Control Module (ECM) Engine Control Module (ECM)
ECM functions Electrically erasable, programmable, read-only ECM functions Electrically erasable, programmable, read-only
Note: memory (EEPROM) Note: memory (EEPROM)
See the Service Text for the ECM installation position. The EEPROM contains necessary program and calibration See the Service Text for the ECM installation position. The EEPROM contains necessary program and calibration
information for the ECM to control powertrain operation. information for the ECM to control powertrain operation.
Replace the ECM if a problem is recognized in the EEPROM. Replace the ECM if a problem is recognized in the EEPROM.
ECM powertrain control program and calibration information ECM powertrain control program and calibration information
consists of the following items. consists of the following items.
• Engine model • Engine model
• Engine number • Engine number
• ECM parts number • ECM parts number
• Diagnostic trouble code • Diagnostic trouble code
• Learning value for interval correction of cylinders • Learning value for interval correction of cylinders
• QR • QR
• Q resistance • Q resistance
• EGR correction learning value • EGR correction learning value
ECM maintenance precautions ECM maintenance precautions
Note: Note:
• Use an ECM with a part number that corresponds to the • Use an ECM with a part number that corresponds to the
main unit. main unit.
• When performing welding on the main unit, be sure to • When performing welding on the main unit, be sure to
disconnect the negative terminal of the battery before disconnect the negative terminal of the battery before
TSWG0008 TSWG0008
performing welding. performing welding.
The ECM constantly monitors information sent from the vari- The ECM is designed to withstand the normal current con- The ECM constantly monitors information sent from the vari- The ECM is designed to withstand the normal current con-
ous sensors and controls each system of the powertrain.The sumption associated with main unit operation. Do not over- ous sensors and controls each system of the powertrain.The sumption associated with main unit operation. Do not over-
ECM implements system function diagnosis, detects prob- load the circuit.When performing a test for disconnections ECM implements system function diagnosis, detects prob- load the circuit.When performing a test for disconnections
lems in system operation, and stores the diagnostic trouble and shorts, unless otherwise specified, do not connect the lems in system operation, and stores the diagnostic trouble and shorts, unless otherwise specified, do not connect the
code in memory along with issuing a warning to the operator ECM circuit to a ground and do not apply any voltage. When code in memory along with issuing a warning to the operator ECM circuit to a ground and do not apply any voltage. When
through the diagnostic lamp.The diagnostic trouble code performing these circuit tests, make sure to use a digital through the diagnostic lamp.The diagnostic trouble code performing these circuit tests, make sure to use a digital
identifies the area in which the problem occurred and sup- tester. identifies the area in which the problem occurred and sup- tester.
ports repair work by the service engineer. ports repair work by the service engineer.
The ECM puts out 5 V and other voltages to supply power to ECM removal The ECM puts out 5 V and other voltages to supply power to ECM removal
the various sensors and switches.The ECM controls output 1. Turn the key switch OFF. the various sensors and switches.The ECM controls output 1. Turn the key switch OFF.
circuits by controlling ground or power supply circuits via one circuits by controlling ground or power supply circuits via one
2. Disconnect the negative terminal of the battery. 2. Disconnect the negative terminal of the battery.
device or another. device or another.
3. To make removal easier, remove parts around the ECM 3. To make removal easier, remove parts around the ECM
ECM and component parts (relay or the like). ECM and component parts (relay or the like).
The ECM is designed to provide superior performance and 4. Remove the ECM connectors from the ECM. (81 pin, 40 The ECM is designed to provide superior performance and 4. Remove the ECM connectors from the ECM. (81 pin, 40
fuel efficiency at the same time it keeps exhaust gas at the pin connectors) fuel efficiency at the same time it keeps exhaust gas at the pin connectors)
regulated level.The ECM monitors various engine functions regulated level.The ECM monitors various engine functions
via sensors such as the crankshaft position (CKP) sensor. 5. Loosen the installation bolts (nuts) and remove the via sensors such as the crankshaft position (CKP) sensor. 5. Loosen the installation bolts (nuts) and remove the
ECM. ECM.
ECM voltage ECM voltage
The ECM applies standard voltage to various switches and Note: The ECM applies standard voltage to various switches and Note:
sensors.The reason the ECM is able to apply voltage in this See the Service Text due to the fact that the installation sensors.The reason the ECM is able to apply voltage in this See the Service Text due to the fact that the installation
way is because of its especially high resistance. The voltage method and position varies depending on the main unit. way is because of its especially high resistance. The voltage method and position varies depending on the main unit.
actually applied to the circuit is low and a test light may not actually applied to the circuit is low and a test light may not
illuminate even if connected to the circuit.Due to the voltmeter illuminate even if connected to the circuit.Due to the voltmeter
input impedance normally used at maintenance factories input impedance normally used at maintenance factories
being too low, an accurate reading value may not be dis- being too low, an accurate reading value may not be dis-
played. Use a 10 M : input impedance digital tester in order played. Use a 10 M : input impedance digital tester in order
to get an accurate voltage reading value. to get an accurate voltage reading value.

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ECM installation ECM installation
ECM installation is the reverse of the removal procedure. ECM installation is the reverse of the removal procedure.
When the ECM has been replaced, make sure to perform When the ECM has been replaced, make sure to perform
EGR valve position learning. EGR valve position learning.
1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Turn the key switch OFF. 2. Turn the key switch OFF.
3. Wait about 10 sec. with the machine in this state. 3. Wait about 10 sec. with the machine in this state.
If EGR valve position learning is not performed, an EGR diag- If EGR valve position learning is not performed, an EGR diag-
nostic trouble code may be detected. nostic trouble code may be detected.
Turning the ECM power OFF Turning the ECM power OFF
For about 10 sec. after turning the key switch OFF, power For about 10 sec. after turning the key switch OFF, power
within the ECM is not yet turned OFF.When it is necessary to within the ECM is not yet turned OFF.When it is necessary to
turn the ECM power OFF to perform tasks such as clearing turn the ECM power OFF to perform tasks such as clearing
the memory, it is necessary to wait for at least 10 sec. after the memory, it is necessary to wait for at least 10 sec. after
the key switch is turned OFF. the key switch is turned OFF.

key switch key switch


ON ON

key switch key switch


OFF OFF

10 sec. 10 sec.

TSWG0176 TSWG0176

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Engine Component Parts Layout Diagram Engine Component Parts Layout Diagram

12 11 10 9 12 11 10 9

8 8
1 1
7 7

2 6 2 6

3 3

5 5
4 4

TSJJ0123 TSJJ0123

Name Name
1. Coolant temperature sensor 1. Coolant temperature sensor
2. SCV 2. SCV
3. Fuel temperature sensor 3. Fuel temperature sensor
4. Oil pressure sensor 4. Oil pressure sensor
5. CKP sensor 5. CKP sensor
6. Common rail pressure sensor 6. Common rail pressure sensor
7. Injector 7. Injector
8. EGR valve 8. EGR valve
9. Boost pressure sensor 9. Boost pressure sensor
10. Boost temperature sensor 10. Boost temperature sensor
11. Glow 11. Glow
12. CMP sensor 12. CMP sensor

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Overall view Overall view

1 Housing left side 1 Housing left side


2 Swing body center section 2 Swing body center section
3 Pump chamber 3 Pump chamber
4 Hydraulic oil tank 4 Hydraulic oil tank
5 Fuel tank 5 Fuel tank

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Pump chamber hydraulic equipment layout (radiator chamber) Pump chamber hydraulic equipment layout (radiator chamber)

1 Hydraulic pump 7 P1 pressure sensor 1 Hydraulic pump 7 P1 pressure sensor


2 Accumulator 8 Pilot pump 2 Accumulator 8 Pilot pump
3 Pilot filter 9 Horsepower control electromagnetic proportional valve 3 Pilot filter 9 Horsepower control electromagnetic proportional valve
4 4 stack solenoid valve 10 N2 pressure sensor 4 4 stack solenoid valve 10 N2 pressure sensor
5 N1 pressure sensor 11 Hydraulic oil temperature sensor 5 N1 pressure sensor 11 Hydraulic oil temperature sensor
6 P2 pressure sensor 6 P2 pressure sensor

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Swing body center section hydraulic equipment layout Swing body center section hydraulic equipment layout

1 Swing motor 1 Swing motor


2 Center joint 2 Center joint
3 Control valve 3 Control valve

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Housing left side hydraulic equipment layout Housing left side hydraulic equipment layout

1 Cushion valve (with heat circuit) 1 Cushion valve (with heat circuit)
2 Swing pilot pressure sensor 2 Swing pilot pressure sensor
3 Oil cooler 3 Oil cooler

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Layout of hydraulic equipment in cab Layout of hydraulic equipment in cab

1 Travel remote control valve 1 Travel remote control valve


2 Upper operation remote control valve 2 Upper operation remote control valve

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4023-51 4023-51

 
 

 
 

 

 

 

 

 

4 4
4 4
4 4 4 4
4 4 4 4
4 4 4 4
4 4 4 4
Location of fuses 4 Location of fuses 4

Location of relays Location of relays


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No. Name No. Name
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R1 Main relay R1 Main relay
R2 Glow relay R2 Glow relay
4' R3 Lamp relay 4' R3 Lamp relay
R4 Lamp relay (CAB) R4 Lamp relay (CAB)
R5 Horn relay L R5 Horn relay L
R6 Horn relay R R6 Horn relay R
No. PART NAME No. PART NAME No. PART NAME No. PART NAME
R7 Speaker relay R R7 Speaker relay R
F7 Back up radio, room lamp 10A F17 Fuel feed pump 20A F7 Back up radio, room lamp 10A F17 Fuel feed pump 20A
R8 Speaker relay L R8 Speaker relay L
F8 Engine pre-heat 30A F18 Clock back monitor 10A F8 Engine pre-heat 30A F18 Clock back monitor 10A
R9 Room lamp relay R9 Room lamp relay
F9 Option line 10A F19 Cigar lighter kab seat 15A F9 Option line 10A F19 Cigar lighter kab seat 15A
R10 Beacon relay R10 Beacon relay
F10 Air-conditioner unit 5A F20 DC converter 10A F10 Air-conditioner unit 5A F20 DC converter 10A
R11 Starter cut relay R11 Starter cut relay
F11 Air-conditioner blower 15A F21 Travel alarm beacon 10A F11 Air-conditioner blower 15A F21 Travel alarm beacon 10A
F12 Air-conditioner compressor 5A F22 Spare (crane) 15A 1 Computer A F12 Air-conditioner compressor 5A F22 Spare (crane) 15A 1 Computer A
F13 Solenoid 10A F23 Elec. fuel pump 10A 2 Relay F13 Solenoid 10A F23 Elec. fuel pump 10A 2 Relay
F14 Wiper washer 15A F24 Lamp (spare) 15A 3 ECM (engine control module) F14 Wiper washer 15A F24 Lamp (spare) 15A 3 ECM (engine control module)
F15 Horn 10A F25 Lock lever (gate) 10A 4 Fuse box F15 Horn 10A F25 Lock lever (gate) 10A 4 Fuse box
F16 Lamp (boom, house) 15A F26 Lamp (cab) 15A 5 Atmospheric pressure sensor F16 Lamp (boom, house) 15A F26 Lamp (cab) 15A 5 Atmospheric pressure sensor
6 TECH II service connector 6 TECH II service connector
7 EST service connector 7 EST service connector
8 Computer A service connector 8 Computer A service connector
9 Computer S service connector 9 Computer S service connector

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Supply pump The SCV (suction control valve) is installed on the supply Supply pump The SCV (suction control valve) is installed on the supply
pump and controls the fuel pressure feed (discharge volume) pump and controls the fuel pressure feed (discharge volume)
to the common rail.The engine control module (ECM) controls to the common rail.The engine control module (ECM) controls
the electrified time to the SCV and controls the fuel discharge the electrified time to the SCV and controls the fuel discharge
volume. volume.

3 3
1 1
2 2

TSJJ0105 TSJJ0105

Name Name
1. SCV 1. SCV
2. Fuel temperature sensor 2. Fuel temperature sensor
TSJJ0001 TSJJ0001
3. Feed pump 3. Feed pump
SCV replacement procedure SCV replacement procedure
Note: Note:
The supply pump uses the force of the engine rotation to In order to make the procedure easy to understand, the dia- The supply pump uses the force of the engine rotation to In order to make the procedure easy to understand, the dia-
raise the fuel pressure and pressure feed fuel to the common grams show the supply pump by itself. raise the fuel pressure and pressure feed fuel to the common grams show the supply pump by itself.
rail.Also, the SCV (suction control valve), fuel temperature rail.Also, the SCV (suction control valve), fuel temperature
(FT) sensor, and feed pump are installed on the supply pump. (FT) sensor, and feed pump are installed on the supply pump.

Note: Note:
See the "Engine" section in the Service Manual for the work See the "Engine" section in the Service Manual for the work
procedures. procedures.

SCV (suction control valve) SCV (suction control valve)

SCV SCV

TSJJ0142 TSJJ0142

1. Remove the SCV connector. 1. Remove the SCV connector.

1 1

TSJJ0106 TSJJ0106

Name Name
1. SCV 1. SCV

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2. Clean the area around the SCV with a cleaning spray. 4. Remove the SCV. 2. Clean the area around the SCV with a cleaning spray. 4. Remove the SCV.

Note: Note: Note: Note:


• Clean the inside of the pump housing and SCV installation • If the SCV is difficult to pull out due to resistance from the • Clean the inside of the pump housing and SCV installation • If the SCV is difficult to pull out due to resistance from the
surface so that there is no dirt or foreign matter adhered O-ring, rotate it from left to right while pulling it out. surface so that there is no dirt or foreign matter adhered O-ring, rotate it from left to right while pulling it out.
when replacing the SCV. • To prevent the entry of foreign matter, gloves should not when replacing the SCV. • To prevent the entry of foreign matter, gloves should not
• When using a cleaning spray, make sure that none gets be worn in performing work from this point on. • When using a cleaning spray, make sure that none gets be worn in performing work from this point on.
inside the SCV connector. inside the SCV connector.
5. Remove the SCV O-ring. 5. Remove the SCV O-ring.
3. Remove the bolts tightening the SCV.(2 locations) 3. Remove the bolts tightening the SCV.(2 locations)
Note: Note:
When removing the O-ring, be careful not to let any foreign When removing the O-ring, be careful not to let any foreign
matter enter the pump housing. matter enter the pump housing.

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6. Check replacement parts. Note: 6. Check replacement parts. Note:
• Use a clean oil such as new engine oil. • Use a clean oil such as new engine oil.
• Do not let any foreign matter become adhered to O-rings. • Do not let any foreign matter become adhered to O-rings.

9. Insert the SCV into the pump housing. 9. Insert the SCV into the pump housing.

Note: Note:
Insert the SCV by hand until it touches the housing. Insert the SCV by hand until it touches the housing.
If the SCV is difficult to insert, lightly rotate it left to right while If the SCV is difficult to insert, lightly rotate it left to right while
inserting it. inserting it.

Note: Note:
Check that the parts are arranged as shown in the diagram. Check that the parts are arranged as shown in the diagram.

7. Set the new O-ring into the O-ring groove. 7. Set the new O-ring into the O-ring groove.

Note: Note:
• Do not touch O-rings with dirty hands. • Do not touch O-rings with dirty hands.
• Make sure that there is no foreign matter in the O-ring • Make sure that there is no foreign matter in the O-ring
groove before continuing with work. groove before continuing with work.
10. Temporarily tighten the SCV installation bolts.(2 loca- 10. Temporarily tighten the SCV installation bolts.(2 loca-
tions) tions)

Note: Note:
Temporarily tighten 2 bolts evenly by hand until the SCV is Temporarily tighten 2 bolts evenly by hand until the SCV is
touching the pump housing. touching the pump housing.

8. Apply oil to the O-ring after setting the O-ring. 8. Apply oil to the O-ring after setting the O-ring.

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Fuel temperature sensor Fuel temperature sensor

11. Tighten the SCV installation bolts to the specified torque. TSWG0011 11. Tighten the SCV installation bolts to the specified torque. TSWG0011

Tightening torque: 6.9 - 10.8 N•m The fuel temperature sensor is installed on the supply pump, Tightening torque: 6.9 - 10.8 N•m The fuel temperature sensor is installed on the supply pump,
and the thermistor changes the resistance in accordance with and the thermistor changes the resistance in accordance with
Note: Note:
the temperature.Resistance is low when the fuel temperature the temperature.Resistance is low when the fuel temperature
After tightening the 2 bolts, retighten the bolts that were tight- After tightening the 2 bolts, retighten the bolts that were tight-
is high and high when fuel temperature is low.The engine is high and high when fuel temperature is low.The engine
ened at the beginning. ened at the beginning.
control module (ECM) applies 5 V to the fuel temperature control module (ECM) applies 5 V to the fuel temperature
sensor through pull-up resistance, calculates the fuel temper- sensor through pull-up resistance, calculates the fuel temper-
ature from the voltage change, and uses this in supply pump ature from the voltage change, and uses this in supply pump
control.Voltage is low if the resistance is small (high tempera- control.Voltage is low if the resistance is small (high tempera-
ture) and high if the resistance is large (low temperature). ture) and high if the resistance is large (low temperature).

Removal Removal
• Do not replace the fuel temperature sensor. • Do not replace the fuel temperature sensor.
• If there is a problem, replace the entire supply pump • If there is a problem, replace the entire supply pump
assembly. assembly.

12. Install the SCV connector. 12. Install the SCV connector.
13. Clean off any fuel that leaked during replacement work. 13. Clean off any fuel that leaked during replacement work.
14. Start the engine and check that there is no fuel leaking 14. Start the engine and check that there is no fuel leaking
from the SCV installation area. from the SCV installation area.

TSJJ0005 TSJJ0005

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Common rail Pressure limiter Common rail Pressure limiter

3 2 3 2 3 2 3 2
1 1 1 1

TSJJ0107 TSJJ0107 TSJJ0107 TSJJ0107

Name Name Name Name


1. Common rail 1. Common rail 1. Common rail 1. Common rail
2. Common rail pressure sensor 2. Common rail pressure sensor 2. Common rail pressure sensor 2. Common rail pressure sensor
3. Pressure limiter 3. Pressure limiter 3. Pressure limiter 3. Pressure limiter

The common rail receives fuel from the supply pump, holds The pressure limiter operates to allow pressure within the The common rail receives fuel from the supply pump, holds The pressure limiter operates to allow pressure within the
the common rail (fuel) pressure, and distributes fuel to each common rail to escape if the pressure in the common rail the common rail (fuel) pressure, and distributes fuel to each common rail to escape if the pressure in the common rail
cylinder.The common rail pressure sensor, flow damper, and becomes abnormally high. cylinder.The common rail pressure sensor, flow damper, and becomes abnormally high.
pressure limiter are installed on the common rail. pressure limiter are installed on the common rail.
Removal Removal
Note: Note:
• Do not replace the pressure limiter. • Do not replace the pressure limiter.
See the "Engine" section in the Service Manual for the work See the "Engine" section in the Service Manual for the work
procedures. • If there is a problem, replace the entire common rail procedures. • If there is a problem, replace the entire common rail
assembly. assembly.

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Common rail pressure sensor Injector Common rail pressure sensor Injector

3 2 3 2
1 1

TSJJ0107 TSJJ0108 TSJJ0107 TSJJ0108


Name Name
The injectors are installed on the cylinder head sections. The injectors are installed on the cylinder head sections.
1. Common rail 1. Common rail
They are controlled by the engine control unit (ECM) and per- They are controlled by the engine control unit (ECM) and per-
2. Common rail pressure sensor 2. Common rail pressure sensor
form fuel injection.The ECM, by internally boosting the injec- form fuel injection.The ECM, by internally boosting the injec-
3. Pressure limiter tor drive voltage and applying it to the injector and by 3. Pressure limiter tor drive voltage and applying it to the injector and by
controlling the electrified time of the injector, controls the fuel controlling the electrified time of the injector, controls the fuel
The common rail pressure sensor is installed on the common injection quantity and injection timing. The common rail pressure sensor is installed on the common injection quantity and injection timing.
rail. It detects the fuel pressure within the common rail, con- rail. It detects the fuel pressure within the common rail, con-
verts the pressure into a voltage signal and sends this to the Note: verts the pressure into a voltage signal and sends this to the Note:
engine control module (ECM).The higher the pressure, the See the "Engine" section in the Service Manual for the work engine control module (ECM).The higher the pressure, the See the "Engine" section in the Service Manual for the work
higher the voltage, and the lower the pressure, the lower the procedures. higher the voltage, and the lower the pressure, the lower the procedures.
voltage.The ECM calculates the actual common rail pressure voltage.The ECM calculates the actual common rail pressure
(fuel pressure) from the signal sent from the sensor and uses (fuel pressure) from the signal sent from the sensor and uses
this for fuel injection control. this for fuel injection control.

Removal Removal
• Do not replace the common rail pressure sensor. • Do not replace the common rail pressure sensor.
• If there is a problem, replace the entire common rail • If there is a problem, replace the entire common rail
assembly. assembly.

TSJJ0002 TSJJ0002

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Coolant temperature sensor Crankshaft position (CKP) sensor Coolant temperature sensor Crankshaft position (CKP) sensor

TSWG0017 TSJJ0132 TSWG0017 TSJJ0132

The coolant temperature sensor is installed on the engine The crankshaft position (CKP) sensor is installed on the fly- The coolant temperature sensor is installed on the engine The crankshaft position (CKP) sensor is installed on the fly-
block, and the thermistor changes the resistance in accor- wheel housing, and the CKP signal is produced from the pro- block, and the thermistor changes the resistance in accor- wheel housing, and the CKP signal is produced from the pro-
dance with the temperature.Resistance is low when the truding part of the flywheel passing the sensor.The engine dance with the temperature.Resistance is low when the truding part of the flywheel passing the sensor.The engine
engine coolant temperature is high and high when engine control module (ECM) identifies the cylinders through CMP engine coolant temperature is high and high when engine control module (ECM) identifies the cylinders through CMP
coolant temperature is low.The engine control module (ECM) signals input from the CMP sensor, determines the crank coolant temperature is low.The engine control module (ECM) signals input from the CMP sensor, determines the crank
applies 5 V to the coolant temperature sensor through pull-up angle, and uses this information for fuel injection control and applies 5 V to the coolant temperature sensor through pull-up angle, and uses this information for fuel injection control and
resistance, calculates the engine coolant temperature from to calculate engine speed.These controls are performed resistance, calculates the engine coolant temperature from to calculate engine speed.These controls are performed
the voltage change, and this is used in various types of con- based on CKP signals, but they are done based on CMP sig- the voltage change, and this is used in various types of con- based on CKP signals, but they are done based on CMP sig-
trol such as fuel injection control.Voltage is low if the resis- nals when there is an abnormality with the CKP sensor trol such as fuel injection control.Voltage is low if the resis- nals when there is an abnormality with the CKP sensor
tance is small (high temperature) and high if the resistance is tance is small (high temperature) and high if the resistance is
large (low temperature). Removal large (low temperature). Removal
• Disconnect the connector, remove the 10 mm installa- • Disconnect the connector, remove the 10 mm installa-
Removal tion bolt, and remove the sensor. Removal tion bolt, and remove the sensor.
• Remove the connector, then remove the sensor with a • Remove the connector, then remove the sensor with a
19 mm wrench. 19 mm wrench.

19mm 19mm

10mm 10mm

TSJJ0012 TSJJ0012

TSJJ0010 Installation TSJJ0010 Installation


Tightening torque: 5 N•m Tightening torque: 5 N•m
Installation Installation
• Apply Loctite 262 to install. • Apply Loctite 262 to install.
Tightening torque: 20 N•m Tightening torque: 20 N•m

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Camshaft position (CMP) sensor Oil pressure sensor Camshaft position (CMP) sensor Oil pressure sensor

TSJJ0132 TSWG0067 TSJJ0132 TSWG0067

The camshaft position (CMP) sensor is installed on the rear The oil pressure sensor is installed near the starter motor of The camshaft position (CMP) sensor is installed on the rear The oil pressure sensor is installed near the starter motor of
section of the cylinder head, and the CMP signal is produced the cylinder block. It detects the engine oil pressure, converts section of the cylinder head, and the CMP signal is produced the cylinder block. It detects the engine oil pressure, converts
from the cam part of the camshaft passing the sensor.The the pressure into a voltage signal, and sends this to the from the cam part of the camshaft passing the sensor.The the pressure into a voltage signal, and sends this to the
engine control module (ECM) identifies the cylinders through engine control module (ECM).The higher the pressure, the engine control module (ECM) identifies the cylinders through engine control module (ECM).The higher the pressure, the
CMP signals input from the CMP sensor, determines the higher the voltage, and the lower the pressure, the lower the CMP signals input from the CMP sensor, determines the higher the voltage, and the lower the pressure, the lower the
crank angle, and uses this information for fuel injection con- voltage. crank angle, and uses this information for fuel injection con- voltage.
trol and to calculate engine speed.These controls are per- trol and to calculate engine speed.These controls are per-
formed based on CKP signals, but they are done based on Removal formed based on CKP signals, but they are done based on Removal
CMP signals when there is an abnormality with the CKP sen- • Remove the connector, then remove the sensor with a CMP signals when there is an abnormality with the CKP sen- • Remove the connector, then remove the sensor with a
sor 27 mm wrench. sor 27 mm wrench.
Removal Removal
• The engine camshaft gear has a scissors gear installed • The engine camshaft gear has a scissors gear installed
on it.When the cam shaft gear is removed, make sure on it.When the cam shaft gear is removed, make sure
that the scissors gear is correctly installed. that the scissors gear is correctly installed.
27mm 27mm
• Disconnect the connector, remove the 10 mm installa- • Disconnect the connector, remove the 10 mm installa-
tion bolt, and remove the sensor. tion bolt, and remove the sensor.

TSJJ0003 TSJJ0003

10mm Installation 10mm Installation


Tightening torque: 40 N•m Tightening torque: 40 N•m

TSJJ0011 TSJJ0011

Installation Installation
• Apply engine oil to the O-ring. • Apply engine oil to the O-ring.
Tightening torque: 5 N•m Tightening torque: 5 N•m

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Atmospheric pressure sensor Atmospheric pressure sensor

TSWG0020 TSWG0020

The atmospheric pressure sensor is installed on the main unit The atmospheric pressure sensor is installed on the main unit
side and converts atmospheric pressure into a voltage sig- side and converts atmospheric pressure into a voltage sig-
nal.The ECM calculates the atmospheric pressure from the nal.The ECM calculates the atmospheric pressure from the
voltage signal and performs correction (high altitude correc- voltage signal and performs correction (high altitude correc-
tion) of the fuel injection quantity according to atmospheric tion) of the fuel injection quantity according to atmospheric
pressure. pressure.

Note: Note:
See the Service Text for the atmospheric pressure sensor See the Service Text for the atmospheric pressure sensor
installation position. installation position.

Suction air temperature sensor Suction air temperature sensor

The suction air temperature sensor is installed on the main The suction air temperature sensor is installed on the main
unit side, and it detects the suction air temperature in order to unit side, and it detects the suction air temperature in order to
optimize the fuel injection control. optimize the fuel injection control.
Tightening torque: 10.8 - 16.3 N•m Tightening torque: 10.8 - 16.3 N•m

Note: Note:
See the Service Text for the suction air temperature sensor See the Service Text for the suction air temperature sensor
installation position. installation position.

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EGR sensor Boost pressure sensor EGR sensor Boost pressure sensor

1 1

2 2

TSJJ0125 TSJJ0125

Name Name
The boost pressure sensor uses a pressure hose between The boost pressure sensor uses a pressure hose between
1. EGR sensor 1. EGR sensor
the boost pressure sensor and the intake pipe to detect the the boost pressure sensor and the intake pipe to detect the
2. EGR valve 2. EGR valve
boost (suction air pressure), converts this pressure into a volt- boost (suction air pressure), converts this pressure into a volt-
age signal and sends this to the engine control module age signal and sends this to the engine control module
Installed within the EGR valve and detects the EGR valve lift (ECM).The higher the pressure, the higher the voltage, and Installed within the EGR valve and detects the EGR valve lift (ECM).The higher the pressure, the higher the voltage, and
amount. the lower the pressure, the lower the voltage.The ECM calcu- amount. the lower the pressure, the lower the voltage.The ECM calcu-
lates the boost (suction pressure) from the voltage signal sent lates the boost (suction pressure) from the voltage signal sent
Note: from the sensor and uses this for fuel injection control. Note: from the sensor and uses this for fuel injection control.
Do not disassemble the EGR sensor.If there is a problem, Do not disassemble the EGR sensor.If there is a problem,
replace the entire EGR valve assembly. Removal replace the entire EGR valve assembly. Removal
• Remove the connector, remove the 2 10 mm installation • Remove the connector, remove the 2 10 mm installation
Removal bolts and hose, and remove the sensor. Removal bolts and hose, and remove the sensor.
• Remove the connector, remove the 12 mm installation • Remove the connector, remove the 12 mm installation
bolt and nut, and remove the EGR valve assembly. bolt and nut, and remove the EGR valve assembly.

10mm 10mm

TSJJ0014 TSJJ0014

TSJJ0009 Installation TSJJ0009 Installation


Tightening torque: 10 N•m Tightening torque: 10 N•m
Installation Installation
Tightening torque: 27 N•m Tightening torque: 27 N•m

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-62 4023-62
Boost temperature sensor DLC (data link connector) Boost temperature sensor DLC (data link connector)

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16

TSWG0023 TSWG0023

The boost temperature sensor is installed on the upstream The DLC (data link connector) is the connector for communi- The boost temperature sensor is installed on the upstream The DLC (data link connector) is the connector for communi-
side of the EGR valve of the intake manifold.This sensor is cation and connection with external diagnosis devices (scan side of the EGR valve of the intake manifold.This sensor is cation and connection with external diagnosis devices (scan
the thermistor type. The internal resistance of the sensor tools) and various controllers. the thermistor type. The internal resistance of the sensor tools) and various controllers.
changes with the temperature. changes with the temperature.

Removal Removal
• Remove the connector, then remove the sensor with a • Remove the connector, then remove the sensor with a
19 mm wrench. 19 mm wrench.

19mm 19mm

TSJJ0013 TSJJ0013

Installation Installation
Tightening torque: 10.8 - 16.3 N•m Tightening torque: 10.8 - 16.3 N•m

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-63 4023-63
Engine Control Module (ECM) Wiring Diagram Engine Control Module (ECM) Wiring Diagram

KEY S/W ECM KEY S/W ECM


LgR530 LR336 24 L371 LgR530 LR336 24 L371
M ST 107 M ST 107
Glow relay 106
G372 CKP sensor Glow relay 106
G372 CKP sensor
BrR339 BW689 BrR339 BW689
R2 10 108 R2 10 108
R11 R11
GrR009 GrR010 GrR337 99 W373 GrR009 GrR010 GrR337 99 W373
46 46
98
L374 CMP sensor 98
L374 CMP sensor
BL687 BL687
100 100
Main relay Main relay
YR332 87 W307 YR332 87 W307
R1 21 R1 21
YR333 82 L317 Common rail YR333 82 L317 Common rail
40 40
90
L318 pressure sensor 90
L318 pressure sensor
F4 R1 F4 R1
RG125 WR330 G327 RG125 WR330 G327
2 101 2 101
WR331 5 WR331 5
94 GB363 U 94 GB363 U
Engine stop S / W 93 GW364 EGR position sensor Engine stop S / W 93 GW364 EGR position sensor
V V
RG126 LG340 92 GR365 RG126 LG340 92 GR365
47 W 47 W

111 WR360 U 111 WR360 U


DIAGNOSTIC Connector DIAGNOSTIC Connector
103 WB361 V M EGR valve motor 103 WB361 V M EGR valve motor
CN51 WL362 CN51 WL362
110 W 110 W

BG691 DIAG S/W PB083 PB082 WB303 BG691 DIAG S/W PB083 PB082 WB303
52 80 52 80

67
Y313 Oil pressure sensor 67
Y313 Oil pressure sensor
BG692 MEMORY CLEAR BrY084 79
BY323 BG692 MEMORY CLEAR BrY084 79
BY323
32 32
RG316 BY RG316 BY
84 Coolant temperature sensor 84 Coolant temperature sensor
YG315 BY YG315 BY
83 Fuel temperature sensor 83 Fuel temperature sensor
RW304 RW304
95 95

91 L314 Boost temperature sensor 91 L314 Boost temperature sensor


Computer A Computer A
GW324 GW324
109 109
GR312 RL GR312 RL
CNC2-6
P040 P042 74 Boost temperature sensor CNC2-6
P040 P042 74 Boost temperature sensor
18 18
PG041 PG043 RW368 PG041 PG043 RW368
CNC2-14 37 105 CNC2-14 37 105
RW369 SCV (suction control valve) RW369 SCV (suction control valve)
113 113
89 RG366 89 RG366

97 RG367 97 RG367

121 W350 Injector #1 121 W350 Injector #1


L352 L352
119 119

Injector #2 Injector #2
BARO BARO
P355 P355
(atmospheric pressure) 118 (atmospheric pressure) 118

sensor sensor
W300 W300
61 Injector #3 61 Injector #3
R351 R351
116 116
YL310 YL310
71 Y353 71 Y353
120 120

G320 G320
60 60
Suction air temperature Injector #4 Suction air temperature Injector #4
sensor 117
G354 sensor 117
G354

G321 L311 G321 L311


72 72
B770 B770
1 1
B771 B771
3 3
B772 B772
4 4
BG670 BG670
43 43
BG671 BG671
62 62
BG672 BG672
81 81
4' 4'

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-64 4023-64
Engine Control Module (ECM) Pin Layout Engine Control Module (ECM) Pin Layout

TSWG0026 TSWG0026

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-65 4023-65
81 pin connectors 81 pin connectors

Pin No. Terminal name Connection Pin No. Terminal name Connection
1 PG-POWER GND 1 PG-POWER GND
2 PS-+B Power supply 2 PS-+B Power supply
3 PG-POWER GND 3 PG-POWER GND
4 PG-POWER GND 4 PG-POWER GND
5 PS-+B Power supply 5 PS-+B Power supply
6 - - 6 - -
7 - - 7 - -
8 - - 8 - -
9 - - 9 - -
10 OS-GLOWR Glow relay 10 OS-GLOWR Glow relay
11 - - 11 - -
12 - - 12 - -
13 - - 13 - -
14 - - 14 - -
15 - - 15 - -
16 - - 16 - -
17 - - 17 - -
18 CC-CAN-H CAN-HIGH 18 CC-CAN-H CAN-HIGH
19 - - 19 - -
20 - - 20 - -
21 OS-MAINR ECM main relay 21 OS-MAINR ECM main relay
22 - - 22 - -
23 - - 23 - -
24 IS-IGKEY Key switch ON signal 24 IS-IGKEY Key switch ON signal
25 - - 25 - -
26 - - 26 - -
27 - - 27 - -
28 - - 28 - -
29 - - 29 - -
30 - - 30 - -
31 - - 31 - -
32 IS-MEMCL Memory clear switch 32 IS-MEMCL Memory clear switch
33 - - 33 - -
34 - - 34 - -
35 - - 35 - -
36 - - 36 - -
37 CC-CAN-L CAN-LOW 37 CC-CAN-L CAN-LOW
38 CC-KW2000 Data link connector 38 CC-KW2000 Data link connector
39 - - 39 - -
40 OS-MAINR ECM main relay 40 OS-MAINR ECM main relay

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-66 4023-66

Pin No. Terminal name Connection Pin No. Terminal name Connection
41 - - 41 - -
42 - - 42 - -
43 PG-SIGN GND 43 PG-SIGN GND
44 - - 44 - -
45 - - 45 - -
46 IS-START Key switch start signal 46 IS-START Key switch start signal
47 ENGSTP Engine stop switch 47 ENGSTP Engine stop switch
48 - - 48 - -
49 - - 49 - -
50 - - 50 - -
51 - - 51 - -
52 IS-DIAG Diagnostic switch 52 IS-DIAG Diagnostic switch
53 - - 53 - -
54 - - 54 - -
55 - - 55 - -
56 - - 56 - -
57 - - 57 - -
58 - - 58 - -
59 - - 59 - -
60 SG-5VRT2 Atmospheric pressure sensor, suction air temperature sensor GND 60 SG-5VRT2 Atmospheric pressure sensor, suction air temperature sensor GND
61 SP-5V2 Atmospheric pressure sensor power supply 61 SP-5V2 Atmospheric pressure sensor power supply
62 PG-SIGN GND 62 PG-SIGN GND
63 - - 63 - -
64 - - 64 - -
65 - - 65 - -
66 - - 66 - -
67 IA-OILPRESS Oil pressure sensor signal 67 IA-OILPRESS Oil pressure sensor signal
68 - - 68 - -
69 - - 69 - -
70 - - 70 - -
71 IA-BARO Atmospheric pressure sensor signal 71 IA-BARO Atmospheric pressure sensor signal
72 IA-IAT Suction air temperature sensor signal 72 IA-IAT Suction air temperature sensor signal
73 - - 73 - -
74 IA-THBST Boost temperature signal 74 IA-THBST Boost temperature signal
75 - - 75 - -
76 - - 76 - -
77 - - 77 - -
78 - - 78 - -
79 SG-5VRT3 Oil pressure sensor, fuel temperature sensor, coolant temperature sensor GND 79 SG-5VRT3 Oil pressure sensor, fuel temperature sensor, coolant temperature sensor GND
80 SP-5V3 Oil pressure sensor power supply 80 SP-5V3 Oil pressure sensor power supply
81 PG-CASE GND 81 PG-CASE GND

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-67 4023-67
40 pin connectors 40 pin connectors

Pin No. Terminal name Connection Pin No. Terminal name Connection
82 IA-PFUEL Common rail pressure sensor signal 82 IA-PFUEL Common rail pressure sensor signal
83 IA-THL Fuel temperature sensor signal 83 IA-THL Fuel temperature sensor signal
84 IA-THW Coolant temperature sensor signal 84 IA-THW Coolant temperature sensor signal
85 - - 85 - -
86 - - 86 - -
87 SP-5V5 Common rail pressure sensor power supply 87 SP-5V5 Common rail pressure sensor power supply
88 - - 88 - -
89 IA-SCVLO SCVLO drive 89 IA-SCVLO SCVLO drive
90 IA-PFUEL Common rail pressure sensor signal 90 IA-PFUEL Common rail pressure sensor signal
91 IA-BPRESS Boost pressure sensor signal 91 IA-BPRESS Boost pressure sensor signal
92 IA-EBMPOS3 EGR valve EGR sensor W 92 IA-EBMPOS3 EGR valve EGR sensor W
93 IA-EBMPOS2 EGR valve EGR sensor V 93 IA-EBMPOS2 EGR valve EGR sensor V
94 IA-EBMPOS1 EGR valve EGR sensor U 94 IA-EBMPOS1 EGR valve EGR sensor U
95 SP-5V4 Boost pressure sensor power supply 95 SP-5V4 Boost pressure sensor power supply
96 - - 96 - -
97 IA-SCVLO SCVLO drive 97 IA-SCVLO SCVLO drive
98 IF-CAMHAL Camshaft position (CMP) sensor signal 98 IF-CAMHAL Camshaft position (CMP) sensor signal
99 SP-CAMHAL Camshaft position (CMP) sensor power supply 99 SP-CAMHAL Camshaft position (CMP) sensor power supply
100 SG-SLD5 Camshaft position (CMP) sensor, common rail pressure sensor shield 100 SG-SLD5 Camshaft position (CMP) sensor, common rail pressure sensor shield
101 SG-5VRT5 Common rail pressure sensor GND 101 SG-5VRT5 Common rail pressure sensor GND
102 - - 102 - -
103 OM-EBM2 EGR valve DC servo motor power supply input V 103 OM-EBM2 EGR valve DC servo motor power supply input V
104 - - 104 - -
105 OS-SCVHI SCVHI drive 105 OS-SCVHI SCVHI drive
106 IF-CRANK- Crankshaft position (CKP) sensor (-) 106 IF-CRANK- Crankshaft position (CKP) sensor (-)
107 IF-CRANK+ Crankshaft position (CKP) sensor (+) 107 IF-CRANK+ Crankshaft position (CKP) sensor (+)
108 SG-SLD4 Crankshaft position (CKP) sensor shield 108 SG-SLD4 Crankshaft position (CKP) sensor shield
109 SG-5VRT4 Boost pressure sensor, coolant temperature sensor, fuel temperature sensor GND 109 SG-5VRT4 Boost pressure sensor, coolant temperature sensor, fuel temperature sensor GND
110 OM-EBM3 EGR valve DC servo motor power supply input W 110 OM-EBM3 EGR valve DC servo motor power supply input W
111 OM-EBM1 EGR valve DC servo motor power supply input U 111 OM-EBM1 EGR valve DC servo motor power supply input U
112 - - 112 - -
113 OS-SCVHI SCVHI drive 113 OS-SCVHI SCVHI drive
114 - - 114 - -
115 - - 115 - -
116 OP-COM2 Injector power supply 2 (No.2 cylinder, No.3 cylinder) 116 OP-COM2 Injector power supply 2 (No.2 cylinder, No.3 cylinder)
117 OS-INJ3 Injector 4 117 OS-INJ3 Injector 4
118 OS-INJ4 Injector 2 118 OS-INJ4 Injector 2
119 OS-INJ1 Injector 1 119 OS-INJ1 Injector 1
120 OS-INJ2 Injector 3 120 OS-INJ2 Injector 3
121 OP-COM1 Injector power supply 1 (No.1 cylinder, No.2 cylinder, No.3 cylinder) 121 OP-COM1 Injector power supply 1 (No.1 cylinder, No.2 cylinder, No.3 cylinder)

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-68 4023-68
Circuit Diagram Circuit Diagram
For how to read the wiring diagram, see "Wiring diagrams". For how to read the wiring diagram, see "Wiring diagrams".
Main relay circuit Main relay circuit

(FUSEB 20A)* (20A)* (FUSEB 20A)* (20A)*

Battery Main relay Battery Main relay

5 E-57 2 E-57 40 E-57 21 E-57 5 E-57 2 E-57 40 E-57 21 E-57

B+ B+ B+ B+

(Engine control module (ECM) (Engine control module (ECM)

TSWG0027 TSWG0027

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


Starter

Lep NST-10-04-001-0EN
C
Starter, glow circuit

Battery B
Generator

(65A) L

(30A)

B C
Safety relay

L S

Glow
relay E

1 H-22 1(( #%% %100'%6+10


*'#6 $ ) ) #%% / 56
5 10
*'#6
B/W 56 1 ( (
#%%
10
1 H-1 56
Key Switch
10 E-57

(Engine control
Glow relay control module (ECM)

Glow
plug

TSHK0025
4023-69

Issued 10-2008
Starter

Lep NST-10-04-001-0EN
C
Starter, glow circuit

Battery B
Generator

(65A) L

(30A)

B C
Safety relay

L S

Glow
relay E

1 H-22 1(( #%% %100'%6+10


*'#6 $ ) ) #%% / 56
5 10
*'#6
B/W 56 1 ( (
#%%
10
1 H-1 56
Key Switch
10 E-57

(Engine control
Glow relay control module (ECM)

Glow
plug
TSHK0025
4023-69

Issued 10-2008
4023-70

CAN LOW CAN HIGH


(Engine control
module (ECM)

Lep NST-10-04-001-0EN
KWP2000

81 E-57 4 E-57 3 E-57 1 E-57 43 E-57 62 E-57 52 E-57 38 E-57 37 E-57 18 E-57
CAN, GND, DLC circuit

1 FL-150 7 FL-150 14 FL-150 6 FL-150

CAN CAN
LOW HIGH
DLC

Shovel controller
5 FL-150 4 FL-150

CAN LOW CAN HIGH

TSJJ0022E

Issued 10-2008
4023-70

CAN LOW CAN HIGH


(Engine control
module (ECM)

Lep NST-10-04-001-0EN
KWP2000

81 E-57 4 E-57 3 E-57 1 E-57 43 E-57 62 E-57 52 E-57 38 E-57 37 E-57 18 E-57
CAN, GND, DLC circuit

1 FL-150 7 FL-150 14 FL-150 6 FL-150

CAN CAN
LOW HIGH
DLC

Shovel controller
5 FL-150 4 FL-150

CAN LOW CAN HIGH


TSJJ0022E

Issued 10-2008
Injector circuit

2 E-423 2 E-422 2 E-411 2 E-414

Lep NST-10-04-001-0EN
Injector Injector Injector Injector
(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)

1 E-423 1 E-422 1 E-411 1 E-414

2 2 2 2 2 2
R P G W L Y

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4) (Engine control
module (ECM)

Feedback Feedback Feedback Feedback


B+ B+

TSJJ0024
4023-71

Issued 10-2008
Injector circuit

2 E-423 2 E-422 2 E-411 2 E-414

Lep NST-10-04-001-0EN
Injector Injector Injector Injector
(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)

1 E-423 1 E-422 1 E-411 1 E-414

2 2 2 2 2 2
R P G W L Y

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4) (Engine control
module (ECM)

Feedback Feedback Feedback Feedback


B+ B+
TSJJ0024
4023-71

Issued 10-2008
4023-72 4023-72
SCV (suction control valve) circuit SCV (suction control valve) circuit

2 E-161 2 E-161

SCV SCV

1 E-161 1 E-161

0.75 0.75 0.75 0.75


R/B R/W R/B R/W

1 H-6 2 H-6 1 H-6 2 H-6

97 E-56 89 E-56 105 E-56 113 E-56 97 E-56 89 E-56 105 E-56 113 E-56

(Engine control (Engine control


module (ECM) module (ECM)
B+ B+

TSHK0016E TSHK0016E

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


Oil pressure
5V 5V sensor signal
5V

Fuel temperature Water temperature Vcc


sensor signal sensor signal

Lep NST-10-04-001-0EN
83 E-56 84 E-56 79 E-56 67 E-56 80 E-56

3 H-6
7 H-20 11 H-20 10 H-20 9 H-20

0.75 0.75 0.75


B/Y L/Y W/B

0.75 0.75 0.75 0.75


Y/G B/Y R/B B/Y

2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

Water
temperature
sensor
Fuel temperature sensor Oil pressure sensor

A
(Engine control
CAN LOW CAN HIGH module (ECM)

37 E-57 18 E-57

Shovel
controller
CAN HIGH CAN LOW
Fuel temperature sensor, coolant temperature sensor, oil pressure sensor circuit

Monitor

TSSA-0026E
4023-73

Issued 10-2008
Oil pressure
5V 5V sensor signal
5V

Fuel temperature Water temperature Vcc


sensor signal sensor signal

Lep NST-10-04-001-0EN
83 E-56 84 E-56 79 E-56 67 E-56 80 E-56

3 H-6
7 H-20 11 H-20 10 H-20 9 H-20

0.75 0.75 0.75


B/Y L/Y W/B

0.75 0.75 0.75 0.75


Y/G B/Y R/B B/Y

2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

Water
temperature
sensor
Fuel temperature sensor Oil pressure sensor

A
(Engine control
CAN LOW CAN HIGH module (ECM)

37 E-57 18 E-57

Shovel
controller
CAN HIGH CAN LOW
Fuel temperature sensor, coolant temperature sensor, oil pressure sensor circuit

Monitor
TSSA-0026E
4023-73

Issued 10-2008
4023-74

(Engine control
Boost pressure module (ECM)
5V sensor signal
CKP sensor signal

Lep NST-10-04-001-0EN
5V

Boost temperature
sensor signal

108 E-56 107 E-56 74 E-56 109 E-56 95 E-56

3 H-20 1 H-20 2 H-20 4 H-20 15 H-20 17 H-20 16 H-20 8 H-20

0.75 B

0.5 0.5 0.5


W/B Gr/B V/W 0.75 0.75 0.75 0.75 0.75
B/R R/L R/L L R/W
CKP sensor, boost temperature sensor, boost pressure sensor circuit

2 E-98 1 E-98 3 E-98 2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

Boost temperature sensor


Boost pressure sensor
CKP sensor

TSJJ0026E

Issued 10-2008
4023-74

(Engine control
Boost pressure module (ECM)
5V sensor signal
CKP sensor signal

Lep NST-10-04-001-0EN
5V

Boost temperature
sensor signal

108 E-56 107 E-56 74 E-56 109 E-56 95 E-56

3 H-20 1 H-20 2 H-20 4 H-20 15 H-20 17 H-20 16 H-20 8 H-20

0.75 B

0.5 0.5 0.5


W/B Gr/B V/W 0.75 0.75 0.75 0.75 0.75
B/R R/L R/L L R/W
CKP sensor, boost temperature sensor, boost pressure sensor circuit

2 E-98 1 E-98 3 E-98 2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

Boost temperature sensor


Boost pressure sensor
CKP sensor
TSJJ0026E

Issued 10-2008
Lep NST-10-04-001-0EN
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal (Engine control
5V
module (ECM)

B+ B+ B+

101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8


18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
CMP sensor, common rail pressure sensor, EGR circuit

O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
L G/Y W/L G/W W/B G/B W/R L/W

0.5 0.5 0.5


L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80

2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113


V

W U

EGR position sensor/EGR motor

CMP sensor Common rail pressure sensor EGR valve

TSJJ0027E
4023-75

Issued 10-2008
Lep NST-10-04-001-0EN
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal (Engine control
5V
module (ECM)

B+ B+ B+

101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8


18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
CMP sensor, common rail pressure sensor, EGR circuit

O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
L G/Y W/L G/W W/B G/B W/R L/W

0.5 0.5 0.5


L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80

2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113


V

W U

EGR position sensor/EGR motor

CMP sensor Common rail pressure sensor EGR valve


TSJJ0027E
4023-75

Issued 10-2008
4023-76 4023-76
Atmospheric pressure sensor, suction air temperature sensor circuit Atmospheric pressure sensor, suction air temperature sensor circuit

Engine control Engine control


Barometric pressure Intake air temperature module (ECM) Barometric pressure Intake air temperature module (ECM)
sensor signal sensor signal sensor signal sensor signal
CAN LOW CAN HIGH CAN LOW CAN HIGH
5V 5V

Vcc Vcc

37 E-57 18 E-57 37 E-57 18 E-57


60 E-57 71 E-57 61 E-57 72 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Shovel Shovel
controller controller

CAN HIGH CAN LOW CAN HIGH CAN LOW


20 H-20 19 H-20 18 H-20 20 H-20 19 H-20 18 H-20

2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Barometric pressure Intake air Barometric pressure Intake air


sensor temperature sensor sensor temperature sensor

TSHK0019E TSHK0019E

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-77 4023-77
Memory clear switch, engine stop switch circuit Memory clear switch, engine stop switch circuit
(*: Specifications will vary depending on the actual machine (fuse capacity or the like), so see the machine manual.) (*: Specifications will vary depending on the actual machine (fuse capacity or the like), so see the machine manual.)

(20A)

(20A)
Key Switch (ON)

Key Switch (ON)


module (ECM)

module (ECM)
Engine control

Engine control
controller

controller
Shovel

Shovel
CAN LOW CAN HIGH

CAN LOW CAN HIGH


E-57

E-57
CAN HIGH

CAN HIGH
18

18
E-57

E-57
CAN LOW

CAN LOW
37

37
Engine stop switch

Engine stop switch


A

A
E-57

E-57
47

47
A

A
E-57

E-57
32

32
B

B
TSSA-0027E TSSA-0027E

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-78 4023-78
Engine Harness Routing Diagram Engine Harness Routing Diagram

13 12 11 10 9 13 12 11 10 9

8 8
1 1
7 7

2 6 2 6

3 3

5 5
4 4
TSJJ0124 TSJJ0124

Name Name
1. Coolant temperature sensor 8. EGR valve 1. Coolant temperature sensor 8. EGR valve
2. SCV 9. Boost pressure sensor 2. SCV 9. Boost pressure sensor
3. Fuel temperature sensor 10. Boost temperature sensor 3. Fuel temperature sensor 10. Boost temperature sensor
4. Oil pressure sensor 11. Glow 4. Oil pressure sensor 11. Glow
5. CKP sensor 12. Overheat switch 5. CKP sensor 12. Overheat switch
6. Common rail pressure sensor 13. CMP sensor 6. Common rail pressure sensor 13. CMP sensor
7. Injector 7. Injector

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


E411 E422 E423 E414
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4

1 2 1 2 1 2 1 2
2 2 2 2 2 2 2 2
L W G R P R Y W

E112
SENSOR:CAM ANGLE (G)

Lep NST-10-04-001-0EN
1 2 3 1
0 .5 0.5 0 .5 5
T O/B Y B/W

GLOW PLUG (No.4)


H1

1 2
0.75 0.75
B/Y Y /G E75
3
0.75 SENSOR:BOOST PRESS
R

SENSOR:WATER 1 2 3 4
1 2 3 0.75 0.75 0.75 0.75
0.75 0.75 0.75 L G/Y G /W G /B
E90 1 R/L L R/W 5 6 7 8
0.75 0.75 0.75 0.75 0.75
G L/W W /L W /R

SWITCH:O/H EGR VALVE


E163 E80
E164
SENSOR:MAT (BOOST TEMP)

1 2
0.75 0.75 1 2 3
E113 R / L B/ R
0.5 0.5 0.5
Gr/B W/B V/W
SENSOR:COMMON RAIL
SENSOR:NE.CRANK
1 2 3
0.5 0.5 0.5 E98
L/ W Br L

1 2
0.75 0.75
B/Y Y/G

SENSOR:FUEL TEMP

E93
1 2 3 4
0.5 0.5 0.75 0.5
W/B G r/ B B V/ W
5 6 7 8
0.5 0.75 0.75 0.75
T B/ W Y/ G R/W
9 10 11 12 1
1 2 0.75 0.75 0.75 0.5
W/B L/Y B/ Y L 5
0.75 0.75 B/W
R/ W R/B 13 14 15 16
0.5 0.5 0.75 0.75
SCV Br L/W B/ R L H22
17 18 19 20
0.75 0.5 0.5
E161 SENSOR:OIL PRESSURE R/L O/B Y
1 2 3
0.75 0.75 0.75
B/ Y L / Y W / B H20
E76

3 2 1
0.75 0.75 0.75
Y/G R/W R/B
4 3 2 1 6 5 4
2 2 0.75 0.75
W R G R
8 7 6 5
4 3 2 1
2 2 2 2 H6
L G P Y 0.75 0.75 0.75 0.75
L G/Y G/W G/B
12 11 10 9 8 7 6 5
0.75 0.75 0.75 0.75
L/W W / L W / B W/R

H12 H8

TSJJ0110
4023-79

Issued 10-2008
E411 E422 E423 E414
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4

1 2 1 2 1 2 1 2
2 2 2 2 2 2 2 2
L W G R P R Y W

E112
SENSOR:CAM ANGLE (G)

Lep NST-10-04-001-0EN
1 2 3 1
0 .5 0.5 0 .5 5
T O/B Y B/W

GLOW PLUG (No.4)


H1

1 2
0.75 0.75
B/Y Y /G E75
3
0.75 SENSOR:BOOST PRESS
R

SENSOR:WATER 1 2 3 4
1 2 3 0.75 0.75 0.75 0.75
0.75 0.75 0.75 L G/Y G /W G /B
E90 1 R/L L R/W 5 6 7 8
0.75 0.75 0.75 0.75 0.75
G L/W W /L W /R

SWITCH:O/H EGR VALVE


E163 E80
E164
SENSOR:MAT (BOOST TEMP)

1 2
0.75 0.75 1 2 3
E113 R / L B/ R
0.5 0.5 0.5
Gr/B W/B V/W
SENSOR:COMMON RAIL
SENSOR:NE.CRANK
1 2 3
0.5 0.5 0.5 E98
L/ W Br L

1 2
0.75 0.75
B/Y Y/G

SENSOR:FUEL TEMP

E93
1 2 3 4
0.5 0.5 0.75 0.5
W/B G r/ B B V/ W
5 6 7 8
0.5 0.75 0.75 0.75
T B/ W Y/ G R/W
9 10 11 12 1
1 2 0.75 0.75 0.75 0.5
W/B L/Y B/ Y L 5
0.75 0.75 B/W
R/ W R/B 13 14 15 16
0.5 0.5 0.75 0.75
SCV Br L/W B/ R L H22
17 18 19 20
0.75 0.5 0.5
E161 SENSOR:OIL PRESSURE R/L O/B Y
1 2 3
0.75 0.75 0.75
B/ Y L / Y W / B H20
E76

3 2 1
0.75 0.75 0.75
Y/G R/W R/B
4 3 2 1 6 5 4
2 2 0.75 0.75
W R G R
8 7 6 5
4 3 2 1
2 2 2 2 H6
L G P Y 0.75 0.75 0.75 0.75
L G/Y G/W G/B
12 11 10 9 8 7 6 5
0.75 0.75 0.75 0.75
L/W W/L W/B W/R

H12 H8
TSJJ0110
4023-79

Issued 10-2008
4023-80 4023-80
E75 E112 E75 E112
Terminal Terminal Terminal Terminal
No. No. No. No.
1 Boost pressure sensor GND 1 CMP shield 1 Boost pressure sensor GND 1 CMP shield
2 Boost pressure sensor Vout 2 CMP GND 2 Boost pressure sensor Vout 2 CMP GND
3 Boost pressure sensor Vcc 3 CMP + 3 Boost pressure sensor Vcc 3 CMP +

E76 E113 E76 E113


Terminal Terminal Terminal Terminal
No. No. No. No.
1 Oil pressure sensor GND 1 Common rail pressure sensor GND 1 Oil pressure sensor GND 1 Common rail pressure sensor GND
2 Oil pressure sensor Vout 2 Common rail pressure sensor Vout 2 Oil pressure sensor Vout 2 Common rail pressure sensor Vout
3 Oil pressure sensor Vcc 3 Common rail pressure sensor Vcc 3 Oil pressure sensor Vcc 3 Common rail pressure sensor Vcc

E80 E161 E80 E161


Terminal Terminal Terminal Terminal
No. No. No. No.
1 EGR Vcc 1 SCV - Hi 1 EGR Vcc 1 SCV - Hi
2 EGR sensor W 2 SCV - Lo 2 EGR sensor W 2 SCV - Lo
3 EGR sensor V 3 EGR sensor V
E163 E163
4 EGR sensor U 4 EGR sensor U
5 EGR GND Terminal 5 EGR GND Terminal
No. No.
6 EGR motor W 6 EGR motor W
1 Boost temperature sensor GND 1 Boost temperature sensor GND
7 EGR motor V 7 EGR motor V
2 Boost temperature sensor + 2 Boost temperature sensor +
8 EGR motor U 8 EGR motor U
E164 E164
E90 E90
Terminal Terminal
Terminal No. Terminal No.
No. No.
1 Overheat switch 1 Overheat switch
1 ECT GND 1 ECT GND
2 ECT + E411 2 ECT + E411
3 ECT (meter) Terminal 3 ECT (meter) Terminal
No. No.
E93 1 OS-INJ1 Signal/injector #1 E93 1 OS-INJ1 Signal/injector #1
Terminal 2 Injector power supply 1 Terminal 2 Injector power supply 1
No. No.
1 Fuel temperature sensor GND E414 1 Fuel temperature sensor GND E414
2 Fuel temperature sensor + Terminal 2 Fuel temperature sensor + Terminal
No. No.
E98 1 OS-INJ3 Signal/injector #4 E98 1 OS-INJ3 Signal/injector #4
Terminal 2 Injector power supply 1 Terminal 2 Injector power supply 1
No. No.
1 CKP Vout E422 1 CKP Vout E422
2 CKP GND Terminal 2 CKP GND Terminal
3 CKP Vcc No. 3 CKP Vcc No.
1 OS-INJ4 Signal/injector #2 1 OS-INJ4 Signal/injector #2
2 Injector power supply 2 2 Injector power supply 2

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-81 4023-81
E423 Terminal E423 Terminal
Terminal No. Terminal No.
No. 5 OS-INJ3 Signal/injector #4 No. 5 OS-INJ3 Signal/injector #4
1 OS-INJ2 Signal/injector #3 6 OS-INJ2 Signal/injector #3 1 OS-INJ2 Signal/injector #3 6 OS-INJ2 Signal/injector #3
2 Injector power supply 2 7 OS-INJ4 Signal/injector #2 2 Injector power supply 2 7 OS-INJ4 Signal/injector #2
8 OS-INJ1 Signal/injector #1 8 OS-INJ1 Signal/injector #1
H1 H1
9 - 9 -
Terminal Terminal
10 - 10 -
No. No.
11 - 11 -
1 Glow 1 Glow
12 - 12 -
H6 H6
H20 H20
Terminal Terminal
No. Terminal No. Terminal
No. No.
1 SCV-Lo 1 SCV-Lo
1 CKP GND 1 CKP GND
2 SCV-Hi 2 SCV-Hi
2 CKP Vout 2 CKP Vout
3 Fuel temperature sensor + 3 Fuel temperature sensor +
3 CKP shield 3 CKP shield
4 ECT (meter) 4 ECT (meter)
4 CKP Vcc 4 CKP Vcc
5 - 5 -
5 CMP Vout 5 CMP Vout
6 Overheat switch 6 Overheat switch
6 CMP/common rail pressure sensor shield 6 CMP/common rail pressure sensor shield
H8 7 ECT + H8 7 ECT +

Terminal 8 Boost pressure sensor Vcc Terminal 8 Boost pressure sensor Vcc
No. 9 Oil pressure sensor Vcc No. 9 Oil pressure sensor Vcc
1 EGR sensor U 10 Oil pressure sensor Vout 1 EGR sensor U 10 Oil pressure sensor Vout
2 EGR sensor V 11 Oil pressure sensor GND 2 EGR sensor V 11 Oil pressure sensor GND
3 EGR sensor W 12 Common rail pressure sensor Vcc 3 EGR sensor W 12 Common rail pressure sensor Vcc
4 EGR Vcc 13 Common rail pressure sensor Vout 4 EGR Vcc 13 Common rail pressure sensor Vout
5 EGR motor U 14 Common rail pressure sensor GND 5 EGR motor U 14 Common rail pressure sensor GND
6 EGR motor V 15 Boost temperature sensor + 6 EGR motor V 15 Boost temperature sensor +
7 EGR motor W 16 Boost pressure sensor Vout 7 EGR motor W 16 Boost pressure sensor Vout
8 EGR GND 17 Boost pressure sensor GND 8 EGR GND 17 Boost pressure sensor GND
18 CMP GND 18 CMP GND
H12 H12
19 CMP Vcc 19 CMP Vcc
Terminal Terminal
20 - 20 -
No. No.
1 - 1 -
H22 H22
2 - 2 -
Terminal Terminal
3 Injector power supply 2 No. 3 Injector power supply 2 No.
4 Injector power supply 1 1 Glow 4 Injector power supply 1 1 Glow

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-82 4023-82
Connector List Connector List
Connector Face Connector Face
Connector Face Connector Face

1 2 3 1 2 3
E-112 E-112
E-56 E-56
003-505 003-505

Engine harness side (male terminal)(black) Engine harness side (male terminal)(black)
Main unit harness side (female terminal)(black) Main unit harness side (female terminal)(black)

E-113 E-113
E-57 E-57

Engine harness side (male terminal)(black) Engine harness side (male terminal)(black)
Main unit harness side (female terminal)(black) Main unit harness side (female terminal)(black)

E-75 1 2 3 E-161 E-75 1 2 3 E-161

003-503 003-503

Engine harness side (male terminal)(gray) Engine harness side (male terminal)(light gray) Engine harness side (male terminal)(gray) Engine harness side (male terminal)(light gray)

E-76 1 2 3 E-76 1 2 3
E-163 1 2 E-163 1 2
003-501 003-501

002-500 002-500
Engine harness side (male terminal)(black) Engine harness side (male terminal)(black)
Engine harness side (male terminal)(black) Engine harness side (male terminal)(black)

E-80 E-80
E-164 E-164
Engine harness side (male terminal)(black) Engine harness side (male terminal)(black)
000-009 000-009

(silver) (silver)
1 2 1 2
3 3
E-90 E-90
003-504 003-504
E-411 E-411
Engine harness side (male terminal)(light gray) Engine harness side (male terminal)(light gray)

Engine harness side (male terminal)(light gray) Engine harness side (male terminal)(light gray)

E-93 E-93

Engine harness side (male terminal)(green) E-414 Engine harness side (male terminal)(green) E-414

1 2 3 Engine harness side (male terminal)(light gray) 1 2 3 Engine harness side (male terminal)(light gray)
E-98 E-98
003-505 003-505

Engine harness side (male terminal)(black) Engine harness side (male terminal)(black)

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-83 4023-83

Connector Face Connector Face Connector Face Connector Face

E-422 H-8 E-422 H-8

Engine harness side (male terminal)(light gray) Engine harness side (male terminal)(black) Engine harness side (male terminal)(light gray) Engine harness side (male terminal)(black)

E-423 H-8 E-423 H-8

Engine harness side (male terminal)(light gray) Actual machine harness side (female terminal) Engine harness side (male terminal)(light gray) Actual machine harness side (female terminal)

FB-124 H-12 FB-124 H-12

Engine harness side (male terminal)(black) Engine harness side (male terminal)(black) Engine harness side (male terminal)(black) Engine harness side (male terminal)(black)

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
FL-150 9 10 11 12 13 14 15 16 H-12 FL-150 9 10 11 12 13 14 15 16 H-12
016-500 016-500

Engine harness side (male terminal) Actual machine harness side (female terminal) Engine harness side (male terminal) Actual machine harness side (female terminal)

1 2 3 4 1 2 3 4
5 6 7 8 5 6 7 8
1 2 3 9 10 11 12 1 2 3 9 10 11 12
FL-269 H-20 13 14 15 16
FL-269 H-20 13 14 15 16
17 18 19 20 17 18 19 20
003-502 020-500 003-502 020-500

Engine harness side (male terminal) Main unit harness side (male terminal) Engine harness side (male terminal) Main unit harness side (male terminal)

4 3 2 1 4 3 2 1
8 7 6 5 8 7 6 5
12 11 10 9 12 11 10 9
H-1 H-20 16 15 14 13
H-1 H-20 16 15 14 13
20 19 18 17 20 19 18 17
000-009 020-501 000-009 020-501

(silver) Actual machine harness side (female terminal) (silver) Actual machine harness side (female terminal)

H-6 H-22 H-6 H-22

Engine harness side (male terminal)(black) Engine harness side (female terminal)(light gray) Engine harness side (male terminal)(black) Engine harness side (female terminal)(light gray)

H-6 H-22 H-6 H-22

Actual machine harness side (female terminal) Actual machine harness side (male terminal) Actual machine harness side (female terminal) Actual machine harness side (male terminal)

Lep NST-10-04-001-0EN Issued 10-2008 Lep NST-10-04-001-0EN Issued 10-2008


4023-84 4023-84

Function Inspection List Function Inspection List


Function Inspection List Function Inspection List
Procedure for sufficiently understanding the trouble symptoms based on the customer's Procedure for sufficiently understanding the trouble symptoms based on the customer's
Inquiry Inquiry
stated description and performing appropriate diagnosis stated description and performing appropriate diagnosis
Trouble diagnosis by service sup- Trouble diagnosis by service sup-
Inspection to specify engine control system problem locations (inspection procedure) Inspection to specify engine control system problem locations (inspection procedure)
port port
Checking the start circuit system Inspection performed when the starter does not operate Checking the start circuit system Inspection performed when the starter does not operate
Checking the start system Inspection performed when the starter operates, but the engine does not start Checking the start system Inspection performed when the starter operates, but the engine does not start
Inspection performed when there is a possibility that there is an abnormality in locations Inspection performed when there is a possibility that there is an abnormality in locations
Checking the fuel system Checking the fuel system
related to the fuel system (inspection procedure) related to the fuel system (inspection procedure)
Inspection performed when there is a possibility that there is an abnormality in locations Inspection performed when there is a possibility that there is an abnormality in locations
Checking the suction air system Checking the suction air system
related to the suction air system (inspection procedure) related to the suction air system (inspection procedure)
Inspection performed when there is a possibility that there is an abnormality in locations Inspection performed when there is a possibility that there is an abnormality in locations
Checking the exhaust system Checking the exhaust system
related to the exhaust system (inspection procedure) related to the exhaust system (inspection procedure)
Inspection performed when there is a possibility that there is an abnormality in locations Inspection performed when there is a possibility that there is an abnormality in locations
Checking the EGR control system Checking the EGR control system
related to the EGR (inspection procedure) related to the EGR (inspection procedure)

Lep NST-10-05-001-0EN Issued 10-2008 Lep NST-10-05-001-0EN Issued 10-2008


4023-85 4023-85
Trouble Diagnosis by Service Support Trouble Diagnosis by Service Support
Trouble diagnosis by service support Cautions in trouble diagnosis by service Trouble diagnosis by service support Cautions in trouble diagnosis by service
Trouble diagnosis by service support is a systematic method support Trouble diagnosis by service support is a systematic method support
for confirming problems that occur due to function deficien- Important: for confirming problems that occur due to function deficien- Important:
cies of the engine control system, and is the starting point for • When there are no complaints about mechanical cies of the engine control system, and is the starting point for • When there are no complaints about mechanical
all mechanical operability complaint diagnosis.By correctly operability, do not perform this diagnosis step as all mechanical operability complaint diagnosis.By correctly operability, do not perform this diagnosis step as
utilizing this diagnosis step, diagnosis time is shortened and long as there are no other indications in other items. utilizing this diagnosis step, diagnosis time is shortened and long as there are no other indications in other items.
replacement of non-defective parts is prevented. replacement of non-defective parts is prevented.
• Before beginning diagnosis, check the service infor- • Before beginning diagnosis, check the service infor-
Test explanation mation. Test explanation mation.
4. When a diagnostic trouble code is detected, see "Proceed • As long as there is no other indication within the 4. When a diagnostic trouble code is detected, see "Proceed • As long as there is no other indication within the
to the relevant DTC diagnosis" and go to the appropriate diagnostic steps, do not delete the diagnostic trou- to the relevant DTC diagnosis" and go to the appropriate diagnostic steps, do not delete the diagnostic trou-
diagnostic trouble code diagnosis.When multiple diagnostic ble codes. diagnostic trouble code diagnosis.When multiple diagnostic ble codes.
trouble codes have been detected, as long as there is no • When an abnormality is found in the engine start trouble codes have been detected, as long as there is no • When an abnormality is found in the engine start
other indication within the diagnostic steps, start diagnosis system, see "Electrical System" in "Engine" of the other indication within the diagnostic steps, start diagnosis system, see "Electrical System" in "Engine" of the
from the diagnostic trouble code with the smallest number. Service Manual. from the diagnostic trouble code with the smallest number. Service Manual.
• The battery should be fully charged. • The battery should be fully charged.
• The condition of the battery cable should be normal • The condition of the battery cable should be normal
and it should be securely connected. and it should be securely connected.
• The ground of the ECM should be securely con- • The ground of the ECM should be securely con-
nected in the correct position. nected in the correct position.

Step Action Value Yes No Step Action Value Yes No


1. Turn the key switch "ON". 1. Turn the key switch "ON".
2. Confirm the diagnostic trouble code. 2. Confirm the diagnostic trouble code.
* Make sure to confirm this as there are Go to relevant diagnostic * Make sure to confirm this as there are Go to relevant diagnostic
1 - Go to step 2. 1 - Go to step 2.
some diagnostic trouble codes in which trouble code display. some diagnostic trouble codes in which trouble code display.
ELEC. PROBLEM does not display. ELEC. PROBLEM does not display.
3. Did a diagnostic trouble code display? 3. Did a diagnostic trouble code display?
Turn the key switch to the "START" position. Go to "Checking the Start Turn the key switch to the "START" position. Go to "Checking the Start
2 - Go to step 3. 2 - Go to step 3.
Did the starter operate? Circuit System". Did the starter operate? Circuit System".
Turn the key switch to the "START" position. Go to "Checking the Start Turn the key switch to the "START" position. Go to "Checking the Start
3 - Go to step 4. 3 - Go to step 4.
Did the engine start? System". Did the engine start? System".
Check that no diagnostic trouble codes have Check that no diagnostic trouble codes have
Go to relevant diagnostic Go to relevant diagnostic
4 been detected. - Go to step 5. 4 been detected. - Go to step 5.
trouble code diagnosis. trouble code diagnosis.
Was a diagnostic trouble code detected? Was a diagnostic trouble code detected?
1. Check whether there are any of the following 1. Check whether there are any of the following
problems. problems.
• Engine stalling • Engine stalling
• Engine hunting, rough idling • Engine hunting, rough idling
• Engine output deficiency, revving problem, • Engine output deficiency, revving problem,
Go to relevant problem Go to relevant problem
5 engine hesitation - System normal 5 engine hesitation - System normal
phenomenon diagnosis. phenomenon diagnosis.
• Great deal of white smoke in exhaust gas • Great deal of white smoke in exhaust gas
• Great deal of black smoke in exhaust gas • Great deal of black smoke in exhaust gas
• Idling speed cannot be adjusted • Idling speed cannot be adjusted
• Idling speed does not go down • Idling speed does not go down
Was a problem detected? Was a problem detected?

Lep NST-10-05-001-0EN Issued 10-2008 Lep NST-10-05-001-0EN Issued 10-2008


4023-86 4023-86
Checking the Start Circuit System Checking the Start Circuit System
Starter safety relay control Starter safety relay control
Starter Starter

B B

C C

Battery B Battery B

Generator Generator

(65A) L (65A) L

(30A) (30A)

B C B C
Safety relay Safety relay

R S R S

Glow Glow
relay E relay E

1 H-22 1(( #%% %100'%6+10 1 H-22 1(( #%% %100'%6+10


*'#6 $ ) ) #%% / 56 *'#6 $ ) ) #%% / 56
5 10 5 10
*'#6 * '# 6
B/W 56 1 ( ( B/W 56 1 ( (
#%% #%%
10 10
1 H-1 56 1 H-1 56

10 E-57 10 E-57

Engine control Engine control


module (ECM) module (ECM)
Glow relay Glow relay
control control

Glow plug Glow plug

TSHK0026 TSHK0026

Circuit explanation In order to detect these causes, the following inspection is Circuit explanation In order to detect these causes, the following inspection is
The starter cut relay on the ECM will turn "ON" if the key necessary. The starter cut relay on the ECM will turn "ON" if the key necessary.
switch is put in the "START" position.If the starter cut relay • Harness connector and ECM connector connection switch is put in the "START" position.If the starter cut relay • Harness connector and ECM connector connection
turns "ON", the starter motor will operate and the engine will problem turns "ON", the starter motor will operate and the engine will problem
start. - Terminal has come out from connector start. - Terminal has come out from connector
Diagnostic aid - Connection between non-matching terminals Diagnostic aid - Connection between non-matching terminals
If an intermittent problem is suspected, the cause may be one - Damage to connector lock If an intermittent problem is suspected, the cause may be one - Damage to connector lock
of the following. - Terminal and wire connection problem of the following. - Terminal and wire connection problem
• Harness connector connection problem • Harness damage • Harness connector connection problem • Harness damage
• Harness routing problem - Inspect the external appearance to check for any • Harness routing problem - Inspect the external appearance to check for any
• Breakage in harness covering due to friction harness damage. • Breakage in harness covering due to friction harness damage.
• Wire disconnection within harness covering - While moving the connector or harness related to a • Wire disconnection within harness covering - While moving the connector or harness related to a
sensor, confirm the display of the related item in the sensor, confirm the display of the related item in the
monitor data indication.The indication change is monitor data indication.The indication change is
showing the trouble location. showing the trouble location.

Lep NST-10-05-001-0EN Issued 10-2008 Lep NST-10-05-001-0EN Issued 10-2008


4023-87 4023-87
Test explanation Test explanation
The numbers below correspond to the diagnosis chart step numbers. The numbers below correspond to the diagnosis chart step numbers.
1. If these diagnostic trouble codes are detected, it may become impossible to start the engine. 1. If these diagnostic trouble codes are detected, it may become impossible to start the engine.
7. If the ECM has not recognized the "START" position signal from the key switch, the starter motor will not operate due to the 7. If the ECM has not recognized the "START" position signal from the key switch, the starter motor will not operate due to the
starter cut relay being "OFF". starter cut relay being "OFF".

Step Action Value Yes No Step Action Value Yes No


1. Turn the emergency stop switch "OFF". 1. Turn the emergency stop switch "OFF".
2. Turn the key switch "ON". Go to diagnosis for the 2. Turn the key switch "ON". Go to diagnosis for the
1 3. Confirm the diagnostic trouble code. - detected diagnostic trouble Go to step 2. 1 3. Confirm the diagnostic trouble code. - detected diagnostic trouble Go to step 2.
Have the diagnostic trouble codes 0340, 0341, code. Have the diagnostic trouble codes 0340, 0341, code.
0615, 1345 or 1625 been detected? 0615, 1345 or 1625 been detected?
1. Use the breaker box or circuit tester to 1. Use the breaker box or circuit tester to
inspect whether any of the conditions below inspect whether any of the conditions below
are present in the circuit between the key are present in the circuit between the key
switch and ECM. switch and ECM.
See "Function Inspection List", "Checking See "Function Inspection List", "Checking
2 the Start System", and "Breaker Box Inspec- - Go to step 9. Go to step 3. 2 the Start System", and "Breaker Box Inspec- - Go to step 9. Go to step 3.
tion Procedure". tion Procedure".
• Disconnection • Disconnection
• High resistance • High resistance
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
Was a problem detected? Was a problem detected?
1. Turn the key switch "OFF". 1. Turn the key switch "OFF".
2. Remove the starter cut relay. 2. Remove the starter cut relay.
3 3. Check the conduction between the starter - Go to step 4. Go to step 5. 3 3. Check the conduction between the starter - Go to step 4. Go to step 5.
cut relay switch side terminals. cut relay switch side terminals.
Was a problem detected? Was a problem detected?
Replace the starter cut relay. Replace the starter cut relay.
4 - Go to step 7. - 4 - Go to step 7. -
Is the action complete? Is the action complete?
Turn the key switch to the "START" position. Turn the key switch to the "START" position.
5 - Go to diagnostic aid. Go to step 8. 5 - Go to diagnostic aid. Go to step 8.
Did the starter operate? Did the starter operate?
1. Inspect whether there is a disconnection or 1. Inspect whether there is a disconnection or
high resistance in the circuits listed below. high resistance in the circuits listed below.
• Between the key switch and starter cut • Between the key switch and starter cut
relay relay
• Between the starter cut relay and safety • Between the starter cut relay and safety
6 - Go to step 9. Go to step 7. 6 - Go to step 9. Go to step 7.
relay relay
• Between the starter cut relay and ground • Between the starter cut relay and ground
• Between the starter cut relay and fuse • Between the starter cut relay and fuse
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
Was a problem detected? Was a problem detected?
1. See the "Electrical System" section in 1. See the "Electrical System" section in
"Engine" of the Service Manual and perform "Engine" of the Service Manual and perform
7 inspection. - Go to step 11. Go to step 8. 7 inspection. - Go to step 11. Go to step 8.
2. Repair as necessary if a problem is detected. 2. Repair as necessary if a problem is detected.
Was a problem detected? Was a problem detected?
8 Is there an EMPS? - Go to step 9. Go to step 11. 8 Is there an EMPS? - Go to step 9. Go to step 11.
1. Check the ECM software version. 1. Check the ECM software version.
2. Perform rewriting if updating the ECM soft- 2. Perform rewriting if updating the ECM soft-
ware version is necessary. ware version is necessary.

9 Note: - Go to step 11. Go to step 10. 9 Note: - Go to step 11. Go to step 10.
When ECM replacement or rewriting is per- When ECM replacement or rewriting is per-
formed, perform EGR learning. formed, perform EGR learning.

Is the action complete? Is the action complete?

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Step Action Value Yes No Step Action Value Yes No


Replace the ECM. Replace the ECM.

Note: Note:
10 When ECM replacement or rewriting is per- - Go to step 11. - 10 When ECM replacement or rewriting is per- - Go to step 11. -
formed, perform EGR learning. formed, perform EGR learning.

Is the action complete? Is the action complete?


Check repair and go to Check repair and go to
Turn the key switch to the "START" position. Turn the key switch to the "START" position.
11 - "Trouble Diagnosis by Ser- Go to step 1. 11 - "Trouble Diagnosis by Ser- Go to step 1.
Did the starter operate? Did the starter operate?
vice Support". vice Support".

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Breaker box inspection procedure Breaker box inspection procedure
For steps in which breaker box usage is indicated, perform For steps in which breaker box usage is indicated, perform
inspection with the following procedure.Return to diagnosis inspection with the following procedure.Return to diagnosis
step after inspection. step after inspection.

Name Name
1. Breaker box 1. Breaker box
2. Circuit tester 2. Circuit tester

Measurement Normal Abnormal Measurement Normal Abnormal


Step Inspection item Inspection method Measurement condition Step Inspection item Inspection method Measurement condition
terminal No. value value terminal No. value value
Disconnection Resistance 46 - Key switch 100 : or 10 M : or Disconnection Resistance 46 - Key switch 100 : or 10 M : or
• Key switch "OFF" • Key switch "OFF"
/high resistance measurement "START" terminal lower higher /high resistance measurement "START" terminal lower higher
2 2
Short circuit with Resistance 10 M : or 100 : or Short circuit with Resistance 10 M : or 100 : or
• Key switch "OFF" 46 - ground • Key switch "OFF" 46 - ground
GND measurement higher lower GND measurement higher lower
Disconnection Resistance • Key switch "OFF" Starter cut relay 100 : or 10 M : or Disconnection Resistance • Key switch "OFF" Starter cut relay 100 : or 10 M : or
3 3
/high resistance measurement • Relay unit Switch side terminal lower higher /high resistance measurement • Relay unit Switch side terminal lower higher
• Key switch "OFF" • Key switch "OFF"
Disconnection Resistance Starter relay 100 : or 10 M : or Disconnection Resistance Starter relay 100 : or 10 M : or
5 • Relay unit 5 • Relay unit
/high resistance measurement Switch side terminal lower higher /high resistance measurement Switch side terminal lower higher
• Relay ON • Relay ON

Inspection procedures for sensors on main unit Inspection procedures for sensors on main unit
Name Name
3 1. Intermediate connectors 3 1. Intermediate connectors
2. Main unit harness 2. Main unit harness
3. Sensor connector 3. Sensor connector
4. Engine harness 4. Engine harness

1. Disconnect the intermediate connectors and perform 1. Disconnect the intermediate connectors and perform
sensor inspection from the engine harness connector. sensor inspection from the engine harness connector.
2. Disconnect the connector from the sensor and short the 2. Disconnect the connector from the sensor and short the
sensor connector wiring. sensor connector wiring.
3. Inspect the harness disconnection from the intermediate 3. Inspect the harness disconnection from the intermediate
connectors. connectors.
• If there is an abnormality in both procedures 1 and 2, • If there is an abnormality in both procedures 1 and 2,
repair the harness and repeat inspection from proce- repair the harness and repeat inspection from proce-
2 1 2 1
dure 1. dure 1.
4 4
• If there is an abnormality in procedure 1 only, replace • If there is an abnormality in procedure 1 only, replace
the sensor. the sensor.

TSWG0197 TSWG0197

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Checking the Start System Checking the Start System

2 E-161 2 E-161

SCV SCV

1 E-161 1 E-161

0.75 0.75 0.75 0.75


R/B R/W R/B R/W

1 H-6 2 H-6 1 H-6 2 H-6

97 E-56 89 E-56 105 E-56 113 E-56 97 E-56 89 E-56 105 E-56 113 E-56
Engine control Engine control
module (ECM) module (ECM)

B+ B+

TSHK0027E TSHK0027E

Checking the start system Diagnostic aid Checking the start system Diagnostic aid
Checking the start system consists of a systematic method of When there is a diagnostic trouble code related to the CKP Checking the start system consists of a systematic method of When there is a diagnostic trouble code related to the CKP
searching for the reason the engine will not start.The follow- sensor and CMP sensor, the engine will not start unless the searching for the reason the engine will not start.The follow- sensor and CMP sensor, the engine will not start unless the
ing items are prerequisites for performing this diagnosis. memory is cleared. ing items are prerequisites for performing this diagnosis. memory is cleared.
• Battery is fully charged and battery cable is securely If an intermittent problem is suspected, the cause may be one • Battery is fully charged and battery cable is securely If an intermittent problem is suspected, the cause may be one
attached. of the following. attached. of the following.
• Engine speed during cranking is normal. • Harness connector connection problem • Engine speed during cranking is normal. • Harness connector connection problem
• Sufficient amount of fuel is filled. • Harness routing problem • Sufficient amount of fuel is filled. • Harness routing problem
• No air is mixed in with fuel. • Breakage in harness covering due to friction • No air is mixed in with fuel. • Breakage in harness covering due to friction
• No abnormalities in air cleaner element and fuel filter. • Wire disconnection within harness covering • No abnormalities in air cleaner element and fuel filter. • Wire disconnection within harness covering
• Correct fuel is being used. In order to detect these causes, the following inspection is • Correct fuel is being used. In order to detect these causes, the following inspection is
necessary. necessary.
Important: • Harness connector and ECM connector connection Important: • Harness connector and ECM connector connection
If a diagnostic trouble code related to the fuel system has problem If a diagnostic trouble code related to the fuel system has problem
been detected, first perform diagnostic trouble code - Terminal has come out from connector been detected, first perform diagnostic trouble code - Terminal has come out from connector
diagnosis. - Connection between non-matching terminals diagnosis. - Connection between non-matching terminals
- Damage to connector lock - Damage to connector lock
- Terminal and wire connection problem - Terminal and wire connection problem

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Test explanation 5. If the engine starts with the SCV connector disconnected, Test explanation 5. If the engine starts with the SCV connector disconnected,
The numbers shown below correspond to step numbers in there is a possible abnormality in the SCV system.If the The numbers shown below correspond to step numbers in there is a possible abnormality in the SCV system.If the
the table. engine does not start, there is a possible abnormality in the the table. engine does not start, there is a possible abnormality in the
4. If the SCV-LOW circuit is short-circuited with the ground, fuel system. 4. If the SCV-LOW circuit is short-circuited with the ground, fuel system.
the SCV drive current will not rise above 900 mA. 6. Check the signal and operation of each sensor and injec- the SCV drive current will not rise above 900 mA. 6. Check the signal and operation of each sensor and injec-
tor. tor.

Step Action Value Yes No Step Action Value Yes No


Turn the switch "OFF" and Turn the switch "OFF" and
1 Is there an emergency stop switch mounted? - Go to step 2. 1 Is there an emergency stop switch mounted? - Go to step 2.
go to step 2. go to step 2.
1. Turn the key switch "ON". 1. Turn the key switch "ON".
Go to diagnosis for the Go to diagnosis for the
2. Crank the engine for 15 sec. 2. Crank the engine for 15 sec.
2 - detected diagnostic trouble Go to step 3. 2 - detected diagnostic trouble Go to step 3.
3. Confirm the diagnostic trouble code.

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