Professional Documents
Culture Documents
* 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.
1001
Section Section
1001 1001
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
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.
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.
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.
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.
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
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.
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
Machine Machine
1 1
2 2
3 3
CT04A171A CT04A171A
Engine Engine
Make and type .................................................................................................................................................................... Make and type ....................................................................................................................................................................
Serial number ..................................................................................................................................................................... Serial number .....................................................................................................................................................................
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)
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).
CP02N001 CP02N001
1 1
2 2
2 2
3 3
3 3
CT02M001 CT02M001
JIS (Japanese Industrial Standard) NO.2 JIS (Japanese Industrial Standard) NO.2
DIN (Deutsche Industrie Normen) DIN 51601 DIN (Deutsche Industrie Normen) DIN 51601
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.
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.
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)
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
3.9 3.9
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
4.0 4.0
Secondary pressure (MPa)
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
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
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
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)
* The weights displayed are approximate weights. * The weights displayed are approximate weights.
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
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
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
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
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
5 5
6 6
2 2
7 7
9 11 9 11
10 8 NI14002-012 10 8 NI14002-012
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
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)
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)
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
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)
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)
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)
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)
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
3 3
2 2
1 NI14002-024 1 NI14002-024
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)
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)
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 (*).
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)
Standard Arm (Dipper) (2500 mm (98.42 in)) Standard Arm (Dipper) (2500 mm (98.42 in))
CX130B 2PC CX130B 2PC
Short Arm (Dipper) (2110 mm (82.68 in)) Short Arm (Dipper) (2110 mm (82.68 in))
CX130B CX130B
Short Arm (Dipper) (2110 mm (83.07 in)) Short Arm (Dipper) (2110 mm (83.07 in))
CX130B (Blade) CX130B (Blade)
Short Arm (Dipper) (2110 mm (82.68 in)) Short Arm (Dipper) (2110 mm (82.68 in))
CX130B 2PC (Blade) CX130B 2PC (Blade)
Long Arm (Dipper) (3010 mm (118.50 in)) Long Arm (Dipper) (3010 mm (118.50 in))
CX130B (LC) CX130B (LC)
Long Arm (Dipper) (3010 mm (118.50 in)) Long Arm (Dipper) (3010 mm (118.50 in))
CX130B 2PC CX130B 2PC
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
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).
[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
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
1 1
NF11002-012 NF11002-012
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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]
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
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
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
RM13001-036 RM13001-036
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
Caution: Be sure to stop the engine before beginning work. Caution: Be sure to stop the engine before beginning work.
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
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
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
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
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
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
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
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
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
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
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.
3001
Section Section
3001 3001
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
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
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
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
NM14002-018 NM14002-018
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
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
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
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
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
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
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
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
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
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
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
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
34 34
34 34 RF11001-136 34 34 RF11001-136
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
Caution: Be sure to stop the engine before beginning work. Caution: Be sure to stop the engine before beginning work.
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
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
RF11001-044 RF11001-044
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
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.
NF11002-092 NF11002-092
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
9 9
10 10
RF11001-065 RF11001-065
[6] Remove the connector (11). [6] Remove the connector (11).
11 11
RF11001-066 RF11001-066
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
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
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
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
RF11001-141 RF11001-141
[7] Connect the injector harness connector (20). [7] Connect the injector harness connector (20).
20 20
RF11001-142 RF11001-142
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
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.
4001
Section Section
4001 4001
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
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.
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
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
(AUTO) (AUTO)
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%.
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
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
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.
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)
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
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
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.
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.
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.
ECM ECM
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.
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).
ECM ECM
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
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.
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
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.
Engine Engine
LED LED
2. Travel Alarm (North America only) 2. Travel Alarm (North America only)
a) Configuration a) Configuration
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
ON ON
Travel alarm Travel alarm
OFF OFF
ON ON
Key switch Key switch
OFF 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
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).
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
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.
Coolant Coolant
temperature temperature
data data
Gauge . The left is the gauge level 3 display state. Gauge . The left is the gauge level 3 display state.
level level
Temperature Temperature
Trouble Trouble
Recovery Recovery
• 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.
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
Trouble Trouble
Recovery Recovery
• 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.
Full Full
. The left is the gauge level 3 display state. . The left is the gauge level 3 display state.
Gauge level Gauge level
Overhead
Overhead
Rated Rated
Full Full
Reserve
Reserve
Reserve Reserve
Empty Empty
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
See See
«Air Conditioner» «Air Conditioner»
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)
LED LED
WASHER WASHER
Washer Washer
Connection Connection
to wiper WIPER (CNT) to wiper WIPER (CNT)
controller controller
WASHER WASHER
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.
OPEN OPEN
CLOSE CLOSE
DOOR DOOR
• 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.
30 seconds 30 seconds
30 seconds 30 seconds 30 seconds 30 seconds 30 seconds 30 seconds 30 seconds 30 seconds
30 30 30 30 30 30
seconds seconds seconds seconds seconds seconds
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
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
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
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.
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
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 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
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
Crusher Crusher
Rotation Rotation
Center OR Center OR
bypass bypass
cut cut
OPTION 1 OPTION 1
Option 2 Option 2
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.
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
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.
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)
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
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.
f) f)
3 seconds 3 seconds
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.
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
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.
1 Computer A 1 Computer A
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.
This page has been left blank intentionally This page has been left blank intentionally
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
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. 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.
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.
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.
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.
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.
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.
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.
Engine speed Injection quantity control Engine speed Injection quantity control
Injection timing control Injection timing control
Cylinder Cylinder
identification signal identification signal
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.
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.)
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.
800{590} 800{590}
-1
2000 min 2000 min-1
750{553} {2000 rpm} 750{553} {2000 rpm}
Torque (N-m) (lbf-ft)
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
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.
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
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.
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.
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}
Key ON Key ON
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
10 seconds 10 seconds
or HR reset or HR reset
10 seconds 10 seconds
10 seconds 10 seconds
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
Normal screen Service support screen Normal screen Service support screen
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)
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
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
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 )
Electrical circuit input /output state ( = OFF, = ON ) Electrical circuit input /output state ( = OFF, = ON )
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
* 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.
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
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
C) H / W-A C) H / W-A
1) Digital input / output 1) Digital input / output
* 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)
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
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
*
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)
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
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 : *
E) H / W-M E) H / W-M
1) Monitor 1) Monitor
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)
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
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.
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
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
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
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
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.
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
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)
3) MAIN 3 3) MAIN 3
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
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 - -
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 - -
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 - -
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 - -
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
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)
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.
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.
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).
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
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.
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)
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. 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 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.
*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.
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.
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
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"
Cancel editing and exit edit mode Value increased Cancel editing and exit edit mode Value increased
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.
QR Code QR Code
QR Code QR Code
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.)
Cursor Cursor
movement movement
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.
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).
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
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
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).
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.
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
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)
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
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
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
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.
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)
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
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.
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
Caution: Be sure stop the engine before beginning work. Caution: Be sure stop the engine before beginning work.
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
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
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
Caution: Be sure stop the engine before beginning work. Caution: Be sure stop the engine before beginning work.
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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)
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
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
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
1 1
3 3
1 1
3 3
1 1
2 2
3 3
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
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)
1 1
9 9
5 5
7 5 7 5
6 6
3 2 3 2
3 3
8 8
4 4
10 10
Starter motor M1 CX210B model 5.0 kW-24 V Starter motor M1 CX210B model 5.0 kW-24 V
Battery G1 Battery G1
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
Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Fuel level sensor R5 Fuel level sensor R5
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
Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Boost pressure B47 Boost pressure B47
sensor sensor
Fuel B3 Fuel B3
temperature temperature
sensor sensor
Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Engine coolant B1 Engine coolant B1
temperature temperature
sensor sensor
Computer A A1 Computer A A1
DC-DC U1 DC-DC U1
converter converter
Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Feed pump S61 Feed pump S61
switch switch
Speakers Speakers
(R & L) (R & L)
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)
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
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
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
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)
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
Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Lever lock limit S51 Lever lock limit S51
switch switch
Cigar lighter E51 Model: 24V Cigar lighter E51 Model: 24V
Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Air conditioner E52 Air conditioner E52
unit unit
Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Receiver drier S52 Receiver drier S52
(switch) (switch)
Evaporator B5 Evaporator B5
sensor sensor
Interior R4 Interior R4
temperature temperature
sensor sensor
Name No. Shape Circuit Remarks Name No. Shape Circuit Remarks
Blower motor M8 Blower motor M8
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)
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
CN. C4
CN. C4
11PIN 22PIN 11PIN 22PIN
CN. C3
CN. C3
6PIN 12PIN 6PIN 12PIN
1PIN 9PIN 1PIN 9PIN
CN. C2
CN. C2
8PIN 16PIN 8PIN 16PIN
CN. C1
CN. C1
13PIN 26PIN 13PIN 26PIN
This page is left blank intentionally This page is left blank intentionally
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
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
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
97 RG367 97 RG367
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
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
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
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
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
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
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
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
RE03003-006 RE03003-006
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
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
RE03003-008 RE03003-008
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
Y27 Y27
F9 Breaker F9 Breaker
LW260 LW260 LY807 LY807 LW260 LW260 LY807 LY807
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
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
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
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
This page is left blank intentionally This page is left blank intentionally
4021
Section Section
4021 4021
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
Lep SM130B4021-0EN Issued 10-08 Lep SM130B4021-0EN Issued 10-08
4021-3 4021-3
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
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.
Name Name
1. Breaker box 1. Breaker box
2. DMM 2. DMM
Breaker-Box Breaker-Box
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.
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.
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.
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?
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.
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.
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).
Yes Yes
Go to step 18. Go to step 18.
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.
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.
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.
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.
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.
SHIELD SHIELD
65*- 65*-
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”
Large amount of engine vibration, idle speed problem Large amount of engine vibration, idle speed problem
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 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.
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?
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.
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.
SHIELD SHIELD
65*- 65*-
Large amount of engine vibration, idle speed problem, output reduction Large amount of engine vibration, idle speed problem, output reduction
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
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.
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 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.
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.
SHIELD SHIELD
65*- 65*-
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
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.
Yes Yes
Go to step 12. Go to step 12.
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
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.
65*- 65*-
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.
Step 1 Step 1
Perform an actual machine diagnosis service Perform an actual machine diagnosis service
support check. support 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.
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.
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.
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.
Step 14 Step 14
1. Start the engine. 1. Start the engine.
2. Check the “Barometric Pressure” display. 2. Check the “Barometric Pressure” display.
Yes Yes
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.
65*- 65*-
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.
Step 1 Step 1
Perform an actual machine diagnosis service Perform an actual machine diagnosis service
support check. support 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.
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.
Step 8 Step 8
Replace the atmospheric pressure sensor. Replace the atmospheric pressure sensor.
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.
No No
Was a problem detected? Was a problem detected?
Yes Yes
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.
65*- 65*-
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"
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.
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
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?
Go to step 8. Go to step 8.
Step 7 Step 7
Replace the IAT sensor. Replace the IAT sensor.
Yes Yes
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.
No No
Was a problem detected? Was a problem detected?
Yes Yes
Go to step 11. Go to step 11.
Go to step 7. Go to step 7.
65*- 65*-
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
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.
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
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 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.
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
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 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.
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.
65*- 65*-
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)
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.
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
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 7 Step 7
Replace the ECT sensor. Replace the ECT sensor.
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
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.
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?
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.
65*- 65*-
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)
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.
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.
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.
Step 9 Step 9
Replace the ECT sensor. Replace the ECT sensor.
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.
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.
65*- 65*-
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"
Resistance (kΩ)
Resistance (kΩ)
Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.
Yes Yes
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 7 Step 7
Replace the supply pump (FT sensor). Replace the supply pump (FT sensor).
Yes Yes
Go to step 11. Go to step 11.
Go to step 8. Go to step 8.
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.
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?
Yes Yes
Go to step 11. Go to step 11.
Go to step 6. Go to step 6.
65*- 65*-
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.
Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
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.
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.
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
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 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.
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.
65*- 65*-
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.
Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.
Yes Yes
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.
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 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.
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.
65*- 65*-
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.
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.
Yes Yes
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.
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.
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.
SHIELD SHIELD
65*- 65*-
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
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.
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.
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.
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.
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 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.
CYLINDER #1 CYLINDER #1
CYLINDER #4 CYLINDER #4
CYLINDER #2 CYLINDER #2
CYLINDER #3 CYLINDER #3
65*- 65*-
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
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)
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.
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.
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.
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 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.
CYLINDER #1 CYLINDER #1
CYLINDER #4 CYLINDER #4
CYLINDER #2 CYLINDER #2
CYLINDER #3 CYLINDER #3
65*- 65*-
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
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)
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.
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.
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.
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 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.
CYLINDER #1 CYLINDER #1
CYLINDER #4 CYLINDER #4
CYLINDER #2 CYLINDER #2
CYLINDER #3 CYLINDER #3
65*- 65*-
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
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)
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.
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.
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.
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 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.
CYLINDER #1 CYLINDER #1
CYLINDER #4 CYLINDER #4
CYLINDER #2 CYLINDER #2
CYLINDER #3 CYLINDER #3
65*- 65*-
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
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)
Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.
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
SHIELD SHIELD
65*- 65*-
Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.
Yes Yes
Go to step 3. Go to step 3.
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.
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.
659) 659)
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.
Step 1 Step 1
Perform an actual machine diagnosis service support Perform an actual machine diagnosis service support
check. check.
Yes Yes
Go to step 3. Go to step 3.
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.
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.
659) 659)
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.
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 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.
Yes Yes
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.
SHIELD SHIELD
65*- 65*-
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.
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 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.
Yes Yes
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.
SHIELD SHIELD
65*- 65*-
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.
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”.
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.
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.
Step 9 Step 9
Replace the CMP sensor. Replace the CMP sensor.
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.
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.
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.
SHIELD SHIELD
65*- 65*-
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.
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.
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.
Step 8 Step 8
Replace the CMP sensor. Replace the CMP sensor.
Yes Yes
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
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.
SHIELD SHIELD
65*- 65*-
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.
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?
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.
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.
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.
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.
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
RELAY R2 RELAY R2
GLOW GLOW
FUSE F3 FUSE F3
(KEY) (KEY)
659) 659)
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
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 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
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.
SHIELD SHIELD
65*- 65*-
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.
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.
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?
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.
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.
SHIELD SHIELD
65*- 65*-
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
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.
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.
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 7 Step 7
Replace the engine oil pressure sensor. Replace the engine oil pressure sensor.
Yes Yes
Go to step 11. Go to step 11.
Go to step 8. Go to step 8.
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.
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.
65*- 65*-
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.
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.
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.
Step 9 Step 9
Replace the engine oil pressure sensor. Replace the engine oil pressure sensor.
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 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.
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.
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.
65*- 65*-
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.
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.
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.
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.
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?
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
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.
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.
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?
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
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.
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.
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.
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.
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.
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 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 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.
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.
SHIELD SHIELD
65*- 65*-
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.
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.
Yes Yes
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)?
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
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?
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.
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 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.
SHIELD SHIELD
65*- 65*-
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.
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.
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.
Step 8 Step 8
Replace the boost temperature sensor. Replace the boost temperature sensor.
Yes Yes
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.
Step 14 Step 14
1. Start the engine 1. Start the engine
2. Check the boost temperature display. 2. Check the boost temperature display.
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.
659) 659)
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.
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.
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.
Step 7 Step 7
Replace the boost temperature sensor. Replace the boost temperature sensor.
Yes Yes
Go to step 11. Go to step 11.
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 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.
Step 13 Step 13
1. Start the engine. 1. Start the engine.
2. Check the boost temperature display. 2. Check the boost temperature display.
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.
659) 659)
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"
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".
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.
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?
Go to step 8. Go to step 8.
Step 8 Step 8
Replace the ECT sensor. Replace the ECT sensor.
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.
Yes Yes
Go to step 6. Go to step 6.
65*- 65*-
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.
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?
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
Yes Yes
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.
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.
Yes Yes
Go to step 22. Go to step 22.
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.
Step 18 Step 18
Replace the injector harness. Replace the injector harness.
Yes Yes
Go to step 23. Go to step 23.
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 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.
65*- 65*-
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"
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?
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
Yes Yes
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.
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.
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?
Yes Yes
Go to step 18. Go to step 18.
Step 18 Step 18
Replace the injector harness. Replace the injector harness.
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.
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 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.
CYLINDER #1 CYLINDER #1
CYLINDER #4 CYLINDER #4
CYLINDER #2 CYLINDER #2
CYLINDER #3 CYLINDER #3
65*- 65*-
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"
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.
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.
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.
SHIELD SHIELD
65*- 65*-
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.
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 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.
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
Step 11 Step 11
Replace the main relay. Replace the main relay.
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.
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.
FUSE F4 FUSE F4
BATTERY BATTERY
(24V) (24V)
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.
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.
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.
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".
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 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.
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.
65*- 65*-
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 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 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.
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.
65*- 65*-
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 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 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.
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.
659) 659)
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".
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 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.
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.
65*- 65*-
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.
Yes Yes
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?
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.
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?
Yes Yes
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"
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.
Step 7 Step 7
Replace computer A. Replace computer A.
Yes Yes
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.
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.
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"
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
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
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.
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
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
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
A A
Turn the key switch OFF and disconnect CN.115. Turn the key switch OFF and disconnect CN.115.
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.
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 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
CONTROLLER A CONTROLLER A
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
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.
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
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
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
A A
Turn the key switch OFF and disconnect CN.116. Turn the key switch OFF and disconnect CN.116.
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.
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 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
CONTROLLER A CONTROLLER A
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
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.
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
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
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
A A
Turn the key switch OFF and disconnect CN.117. Turn the key switch OFF and disconnect CN.117.
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.
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 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
CONTROLLER A CONTROLLER A
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
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.
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
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
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
A A
Turn the key switch OFF and disconnect CN.118. Turn the key switch OFF and disconnect CN.118.
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.
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 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
CONTROLLER A CONTROLLER A
Overload pressure sensor signal abnormality Overload pressure sensor signal abnormality
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
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.
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
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
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
A A
Turn the key switch OFF and disconnect CN.123. Turn the key switch OFF and disconnect CN.123.
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.
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 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
CONTROLLER A CONTROLLER A
Bottom pressure sensor signal abnormality Bottom pressure sensor signal abnormality
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
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.
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
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
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
A A
Turn the key switch OFF and disconnect CN.CR9. Turn the key switch OFF and disconnect CN.CR9.
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.
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 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
CONTROLLER B CONTROLLER B
Rod pressure sensor signal abnormality Rod pressure sensor signal abnormality
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
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.
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
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
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
A A
Turn the key switch OFF and disconnect CN.CR10. Turn the key switch OFF and disconnect CN.CR10.
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.
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 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
CONTROLLER B CONTROLLER B
Upper pressure sensor signal abnormality Upper pressure sensor signal abnormality
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
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.
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
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
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
A A
Turn the key switch OFF and disconnect CN.120. Turn the key switch OFF and disconnect CN.120.
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.
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 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
CONTROLLER A CONTROLLER A
Swing pressure sensor signal abnormality Swing pressure sensor signal abnormality
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
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.
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
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
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
A A
Turn the key switch OFF and disconnect CN.119. Turn the key switch OFF and disconnect CN.119.
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.
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 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
CONTROLLER A CONTROLLER A
Travel pressure sensor signal abnormality Travel pressure sensor signal abnormality
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
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.
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
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
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
A A
Turn the key switch OFF and disconnect CN.121. Turn the key switch OFF and disconnect CN.121.
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.
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 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
CONTROLLER A CONTROLLER A
Fuel level sensor signal abnormality Fuel level sensor signal abnormality
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
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
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
A A
Turn the key switch OFF and connect Turn the key switch OFF and connect
CN.135. CN.135.
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
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
CONTROLLER A CONTROLLER A
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)
Oil temperature sensor signal abnormality Oil temperature sensor signal abnormality
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
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
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
A A
Turn the key switch OFF and connect Turn the key switch OFF and connect
CN.125. CN.125.
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
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
CONTROLLER A CONTROLLER A
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
*: 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.
Boom angle sensor signal abnormality Boom angle sensor signal abnormality
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
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.
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
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
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
A A
Turn the key switch OFF and disconnect CN.11. Turn the key switch OFF and disconnect CN.11.
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.
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 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
Arm angle sensor signal abnormality Arm angle sensor signal abnormality
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
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.
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
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
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
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.
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.
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 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
CONTROLLER B CONTROLLER B
Return filter clogging pressure switch signal Return filter clogging pressure switch signal
abnormality abnormality
Diagnostic trouble code: 7063 displayed. Diagnostic trouble code: 7063 displayed.
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.
Yes Yes
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
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
Return filter clogging pressure switch signal Return filter clogging pressure switch signal
abnormality abnormality
Diagnostic trouble code: 7063 displayed. Diagnostic trouble code: 7063 displayed.
Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.134. disconnect CN.134.
Yes Yes
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
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
CONTROLLER A CONTROLLER A
Swing brake solenoid signal abnormality Swing brake solenoid signal abnormality
Diagnostic trouble code: 7200 displayed. Diagnostic trouble code: 7200 displayed.
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.
Yes Yes
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
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
A A
Go to A. Go to A.
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
Yes Yes
Travel high-speed solenoid signal abnormality Travel high-speed solenoid signal abnormality
Diagnostic trouble code: 7201 displayed. Diagnostic trouble code: 7201 displayed.
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.
Yes Yes
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
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
A A
Go to A. Go to A.
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
Yes Yes
Pressure boost solenoid signal abnormality Pressure boost solenoid signal abnormality
Diagnostic trouble code: 7202 displayed. Diagnostic trouble code: 7202 displayed.
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.
Yes Yes
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
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
A A
Go to A. Go to A.
A A
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
Yes Yes
ENGINE ENGINE
CONTROLLER CONTROLLER
BRAKER/CRUSHER BRAKER/CRUSHER
PILOT PRESS. PILOT PRESS.
•
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.
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
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
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.
A A
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
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
CONTROLLER A CONTROLLER A
Air conditioner coolant temperature signal Air conditioner coolant temperature signal
abnormality abnormality
•
Diagnostic trouble code: 7209 ( ) is displayed on •
Diagnostic trouble code: 7209 ( ) is displayed on
the service support DIAG screen. the service support DIAG screen.
Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.28. disconnect CN.28.
Yes Yes
Yes Yes
Cause and solution Cause and solution
Computer A defect Computer A defect
Replacement Replacement
Diagnostic trouble code: 7210 displayed. Diagnostic trouble code: 7210 displayed.
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.
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
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
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.
A A
Yes Yes
Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.CR4. disconnect CN.CR4.
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
CONTROLLER A CONTROLLER A
Rotating light, bucket lock signal abnormality Rotating light, bucket lock signal abnormality
Diagnostic trouble code: 7211 displayed. Diagnostic trouble code: 7211 displayed.
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.
Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.19. disconnect CN.19.
Yes Yes
Yes Yes
A A
Go to A. Go to A.
A A
Key switch ON Key switch ON
Yes Yes
CONTROLLER B CONTROLLER B
FUSE F5 FUSE F5
CONTROLLER A (CONT) CONTROLLER A (CONT)
Pump horsepower proportional valve signal Pump horsepower proportional valve signal
abnormality abnormality
Diagnostic trouble code: 7240 displayed. Diagnostic trouble code: 7240 displayed.
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
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
A A
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 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
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
B B
Go to B. Go to B.
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
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
P1 flow control proportional valve signal P1 flow control proportional valve signal
abnormality abnormality
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.
No No
Diagnostic trouble code: 7241 displayed. Diagnostic trouble code: 7241 displayed.
Yes Yes
A A
Go to A. Go to A.
Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.114. disconnect CN.114.
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
A A
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 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
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
B B
Go to B. Go to B.
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
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
•
Diagnostic trouble code: 7400 ( ) is displayed •
Diagnostic trouble code: 7400 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.
•
Diagnostic trouble code: 7404 ( ) is displayed •
Diagnostic trouble code: 7404 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.
Inspect the hydraulic oil temperature. Inspect the hydraulic oil temperature.
CONTROLLER A CONTROLLER A
•
Diagnostic trouble code: 7405 ( ) is displayed •
Diagnostic trouble code: 7405 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.
•
Diagnostic trouble code: 7420 ( ) is displayed •
Diagnostic trouble code: 7420 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.
Turn the key switch OFF and Turn the key switch OFF and
disconnect CN.110. disconnect CN.110.
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
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.
A A
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.
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
RELAY R11 FUSIBLE LINK FUSIBLE LINK RELAY R11 FUSIBLE LINK FUSIBLE LINK
STARTER CUT STARTER CUT
ALTERNATOR ALTERNATOR
•
Diagnostic trouble code: 7421 ( ) is displayed •
Diagnostic trouble code: 7421 ( ) 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 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.
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
CONTROLLER A CONTROLLER A
•
Diagnostic trouble code: 7422 ( ) is displayed •
Diagnostic trouble code: 7422 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.
Clean or replace the air cleaner Clean or replace the air cleaner
element. element.
•
Diagnostic trouble code: 7423 ( ) is displayed •
Diagnostic trouble code: 7423 ( ) 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 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.
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 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
"CHECK HYD. OIL FILTER" display appears. "CHECK HYD. OIL FILTER" display appears.
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.
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
Diagnostic trouble code: 7600 displayed. Diagnostic trouble code: 7600 displayed.
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
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
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.
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.
A A
Turn the key switch OFF and Turn the key switch OFF and
connect CN.A0. connect CN.A0.
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.
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
Monitor Monitor
communication communication
abnormality abnormality
Diagnostic trouble code: 7601 displayed. Diagnostic trouble code: 7601 displayed.
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
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
Diagnostic trouble code: 7602 displayed. Diagnostic trouble code: 7602 displayed.
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
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
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
Diagnostic trouble code: 7605 displayed. Diagnostic trouble code: 7605 displayed.
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
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
CONTROLLER A CONTROLLER A
ENGINE ENGINE
CONTROLLER CONTROLLER
•
Diagnostic trouble code: 7606 ( ) is displayed •
Diagnostic trouble code: 7606 ( ) is displayed
on the service support DIAG screen. on the service support DIAG screen.
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
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
........................................................................................................................................................ ........................................................................................................................................................
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
Lep SM130B4023-0EN Issued 10-2008 Lep SM130B4023-0EN Issued 10-2008
4023-3 4023-3
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
5884003850 5884003850
• 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.
"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.
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
SHIELD SHIELD
655#
655#
CONTROLLER A CONTROLLER A
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
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.
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#'
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”.
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.
DTC: 7000 P1 Pressure sensor signal fault DTC: 7000 P1 Pressure sensor signal fault
Turn the key switch to “ON”. Turn the key switch to “ON”.
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
Check the short circuit to power Check the short circuit to power
supply. supply.
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
A A
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
PRESS. SENSOR (P1) PRESS. SENSOR (P1)
655# 655#
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
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
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.
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.
«Difference in temperature change by state of combustion» «Difference in temperature change by state of combustion»
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
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, 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
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
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
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
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.
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)
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.
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 SCV
Injector Injector
TSHK0001 TSHK0001
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
30 30
System recognition engine speed System recognition engine speed
TSWG0175 TSWG0175
TSWG0173 TSWG0173
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)
ECM ECM
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.
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
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.
Injector Injector
TSJJ0102E TSJJ0102E
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
1 0 1 0
( (
56
56
1(
1(
*1 *1
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)
Accelerator position
Accelerator position
No idle EGR No idle EGR
TSJJ0159E TSJJ0159E
Outlet port of coolant Inlet port of coolant Outlet port of coolant Inlet port of coolant
EGR cooler EGR cooler
TSJJ0153E TSJJ0153E
10 sec. 10 sec.
TSWG0176 TSWG0176
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
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
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
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
No. Name No. Name
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
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
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 SCV
TSJJ0142 TSJJ0142
1 1
TSJJ0106 TSJJ0106
Name Name
1. SCV 1. SCV
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.
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
3 2 3 2 3 2 3 2
1 1 1 1
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.
3 2 3 2
1 1
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
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
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
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
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.
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.
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
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
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
97 RG367 97 RG367
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
TSWG0026 TSWG0026
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
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
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)
B+ B+ B+ B+
TSWG0027 TSWG0027
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
(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
(Engine control
Glow relay control module (ECM)
Glow
plug
TSHK0025
4023-69
Issued 10-2008
4023-70
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
CAN CAN
LOW HIGH
DLC
Shovel controller
5 FL-150 4 FL-150
TSJJ0022E
Issued 10-2008
4023-70
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
CAN CAN
LOW HIGH
DLC
Shovel controller
5 FL-150 4 FL-150
Issued 10-2008
Injector circuit
Lep NST-10-04-001-0EN
Injector Injector Injector Injector
(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)
2 2 2 2 2 2
R P G W L Y
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)
TSJJ0024
4023-71
Issued 10-2008
Injector circuit
Lep NST-10-04-001-0EN
Injector Injector Injector Injector
(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)
2 2 2 2 2 2
R P G W L Y
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)
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
97 E-56 89 E-56 105 E-56 113 E-56 97 E-56 89 E-56 105 E-56 113 E-56
TSHK0016E TSHK0016E
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
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
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
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
0.75 B
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
0.75 B
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
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
W U
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
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
W U
Issued 10-2008
4023-76 4023-76
Atmospheric pressure sensor, suction air temperature sensor circuit Atmospheric pressure sensor, suction air temperature sensor circuit
Vcc Vcc
Shovel Shovel
controller controller
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
TSHK0019E TSHK0019E
(20A)
(20A)
Key Switch (ON)
module (ECM)
Engine control
Engine control
controller
controller
Shovel
Shovel
CAN LOW CAN HIGH
E-57
CAN HIGH
CAN HIGH
18
18
E-57
E-57
CAN LOW
CAN LOW
37
37
Engine stop switch
A
E-57
E-57
47
47
A
A
E-57
E-57
32
32
B
B
TSSA-0027E TSSA-0027E
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
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
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
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
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
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 +
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
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)
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)
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)
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)
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)
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)
Actual machine harness side (female terminal) Actual machine harness side (male terminal) Actual machine harness side (female terminal) Actual machine harness side (male terminal)
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
10 E-57 10 E-57
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.
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.
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.
Name Name
1. Breaker box 1. Breaker box
2. Circuit tester 2. Circuit tester
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
2 E-161 2 E-161
SCV SCV
1 E-161 1 E-161
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