ZX200-3 E Manual 1

Introduction
This Troubleshooting Manual describes the structure and the troubleshooting of

electronic control fuel injection system (common rail type) in 4HK1 and 6HK1
industrial engines.
Use this manual sufficiently to perform service work properly and quickly.
Hitachi Construction Machinery Co.,Ltd

General Contents
Control System
Electronic control fuel injection system (Common rail type)
Engine Manual (2/2)

Disassemble and Assemble Engine
General Information
Engine Mechanical (4HK1、6HK1)
Cooling System
Fuel System
Engine Electrical
Exhaust System and Turbocharger
Electronic Control Fuel Injection System (Common Rail Type) 1E-1
Control System
Electronic Control Fuel Injection System (Common Rail Type)
Table of Contents
How to Use This Manual ....................................... 1E-4 How to Use Breaker Box ...................................1E-185
How to use this manual...................................... 1E-4 Breaker box inspection procedure .................1E-185
Table of abbreviation.......................................... 1E-5 Engine Control System .....................................1E-188
About colors of wirings ....................................... 1E-6 Description of function and operation for engine
About wiring diagrams........................................ 1E-7 control (common rail) system .........................1E-188
How to read trouble diagnosis section ............... 1E-8 Engine control module (ECM) ........................1E-196
Precautions on Service Work.............................. 1E-10 Engine component location diagram.............. 1E-198
Electrical system .............................................. 1E-10 Wiring diagram of engine control module (ECM)
Fuel injection system........................................ 1E-11 .......................................................................1E-211
Procedure of Trouble Diagnosis.......................... 1E-12 Pin arrangement of engine control module (ECM)
About trouble diagnosis.................................... 1E-12 .......................................................................1E-213
Trouble diagnostic procedure........................... 1E-13 Circuit diagram ...............................................1E-217
Interview........................................................... 1E-14 Engine harness location................................. 1E-234
Pre-inspection .................................................. 1E-16 Connector list .................................................1E-245
Trouble diagnosis............................................. 1E-16 List of Function Checks .....................................1E-248
How to read DTC ............................................. 1E-17 List of function checks....................................1E-248
Confirmation after repair .................................. 1E-19 OBD system check.........................................1E-249
List of final check items .................................... 1E-19 Diagnosis lamp illumination circuit system check
How to clear DTC............................................. 1E-20 .......................................................................1E-251
Trouble diagnosis with scan tool ...................... 1E-21 Diagnosis lamp blinking circuit system check 1E-253
How to Use Trouble Diagnosis-Related Tool ...... 1E-25 Scan tool power supply circuit system check. 1E-257
Tech2 ............................................................... 1E-25 Scan tool communication circuit system check
Rewriting of Q adjust correction data by Tech2 .......................................................................1E-259
......................................................................... 1E-47 Starting circuit system check..........................1E-263
Injector ID code (No. 1 cylinder - No. 6 cylinder) Starting system check ....................................1E-269
registration setting using Tech2 ....................... 1E-54 Fuel system check .........................................1E-272
ID code upload (Tech2).................................... 1E-62 Intake system check.......................................1E-274
ID code download (ECM) ................................. 1E-67 Exhaust system check ...................................1E-275
TIS2000............................................................ 1E-72 EGR control system check.............................1E-276
How to Inspect Injector........................................ 1E-82 QOS system check ........................................ 1E-279
How to use injector checker ............................. 1E-82 List of Diagnostic Trouble Codes ......................1E-284
Method to identify using non-contact infrared List of diagnostic trouble codes for Hitachi
thermometer..................................................... 1E-86 Construction Machinery Co., Ltd....................1E-284
Injector balance test (Tech2)............................ 1E-87 DTC: P0087 (Flash code 227) Common rail low
Flash Tool (EMPS).............................................. 1E-88 pressure fault (No pressure feed in supply pump)
Introduction ...................................................... 1E-88 .......................................................................1E-308
Cautions ........................................................... 1E-88 DTC: P0088 (Flash code 118) Common rail pressure
EMPS Component Parts .................................. 1E-90 is abnormally high (1st or 2nd stage) .............1E-316
ECM (hardware) compatibility .......................... 1E-91 DTC: P0089 (Flash code 151) Common rail pressure
System Requirements for EMPS Software fault (Excessive pressure feed in supply pump)
(Recommended) .............................................. 1E-91 .......................................................................1E-321
EMPS (software) Setup Procedure .................. 1E-92 DTC: P0090 (Flash code 247) SCV drive system
EMPS Operation Procedure................................ 1E-95 open circuit, +B short or ground short ............1E-326
1. Preparation................................................... 1E-95 DTC: P0107 (Flash code 71) Barometric pressure
2. ECM Reflash ................................................ 1E-97 sensor circuit input is low (open circuit or ground
3. Injector Replacement ................................. 1E-115 short) ..............................................................1E-332
4. Replace ECM (Same Model) ..................... 1E-128 DTC: P0108 (Flash code 71) Barometric pressure
5. Factory Setting ........................................... 1E-155 sensor circuit input is high (+5V short) ...........1E-339
6. Recover Point............................................. 1E-166 DTC: P0112 (Flash code 22) Intake air temperature
7. Error Messages.......................................... 1E-168 sensor fault (low voltage fault, GND short, short
8. Error Code List ........................................... 1E-175 circuit).............................................................1E-345
1E-2 Electronic Control Fuel Injection System (Common Rail Type)
DTC: P0113 (Flash code 22) Intake air temperature DTC: P0606 (Flash code 51) CPU fault .........1E-513
sensor fault (high voltage fault, open circuit or short to DTC: P0606 (Flash code 52) CPU monitoring IC fault
power supply circuit) ...................................... 1E-351 .......................................................................1E-515
DTC: P0117 (Flash code 23) Engine coolant DTC: P0611 (Flash code 34) Charge circuit fault
temperature sensor fault (low voltage fault, GND (bank 1) ..........................................................1E-517
short, short circuit).......................................... 1E-359 DTC: P0612 (Flash code 34) Charge circuit fault
DTC: P0118 (Flash code 23) Engine coolant (bank 2) ..........................................................1E-520
temperature sensor input is high (open circuit or short DTC: P0650 (Flash code 77) Diagnosis lamp circuit
to power supply)............................................. 1E-365 fault ................................................................1E-523
DTC: P0182 (Flash code 211) Fuel temperature DTC: P1093 (Flash code 227) No pump pressure
sensor fault (low voltage fault, GND short) .... 1E-372 feed ................................................................1E-529
DTC: P0183 (Flash code 211) Fuel temperature DTC: P1095 (Flash code 225) Pressure limiter open
sensor fault (high voltage fault, open circuit or short to .......................................................................1E-538
power supply circuit) ...................................... 1E-378 DTC: P1112 (Flash code 295) Boost temperature
DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, ground short) .1E-547
sensor fault (low voltage fault, short circuit) ... 1E-386 DTC: P1113 (Flash code 295) Boost temperature
DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault, open circuit, short to
sensor fault (high voltage fault) ...................... 1E-392 power supply circuit) ......................................1E-554
DTC: P0201 (Flash code 271) Open circuit in DTC: P1173 (Flash code 542) Overheat........1E-561
injection nozzle #1 drive system .................... 1E-398 DTC: P1225 (Flash code 31) Idle UP/DOWN switch
DTC: P0202 (Flash code 272) Open circuit in fault ................................................................1E-566
injection nozzle #2 drive system .................... 1E-404 DTC: P1261 (Flash code 158) Injection nozzle
DTC: P0203 (Flash code 273) Open circuit in common 1 drive system fault .........................1E-570
injection nozzle #3 drive system .................... 1E-410 DTC: P1262 (Flash code 159) Injection nozzle
DTC: P0204 (Flash code 274) Open circuit in common 2 drive system fault .........................1E-581
injection nozzle #4 drive system .................... 1E-416 DTC: P1271 (Flash code 24) Accelerator sensor 1-2
DTC: P0205 (Flash code 275) Open circuit in comparison fault.............................................1E-592
injection nozzle #5 drive system .................... 1E-422 DTC: P1277 (Flash code 24) Accelerator sensor 1
DTC: P0206 (Flash code 276) Open circuit in fault (low voltage fault) ...................................1E-599
injection nozzle #6 drive system .................... 1E-427 DTC: P1278 (Flash code 24) Accelerator sensor 1
DTC: P0219 (Flash code 543) Overrun ......... 1E-432 fault (high voltage fault) ..................................1E-605
DTC: P0237 (Flash code 32) Boost sensor pressure DTC: P1282 (Flash code 24) Accelerator sensor 2
fault (low voltage fault, open circuit)............... 1E-434 fault (low voltage fault) ...................................1E-610
DTC: P0238 (Flash code 32) Boost pressure sensor DTC: P1283 (Flash code 24) Accelerator sensor 2
fault (high voltage fault, short to power supply circuit, fault (high voltage fault) ..................................1E-616
ground open circuit) ....................................... 1E-441 DTC: P1345 (Flash code 16) Cam sensor out of
DTC: P0335 (Flash code 15) Crank sensor fault (no phase .............................................................1E-621
signal)............................................................. 1E-448 DTC: P1625 (Flash code 416) Main relay fault
DTC: P0336 (Flash code 15) Crank sensor fault .......................................................................1E-627
(signal fault).................................................... 1E-454 DTC: P1630 (Flash code 36) A/D conversion fault
DTC: P0340 (Flash code 14) Cam sensor fault (no .......................................................................1E-634
signal)............................................................. 1E-460 DTC: P1631 (Flash code 55) Voltage fault in 5-V
DTC: P0341 (Flash code 14) Cam sensor fault power supply 1 ...............................................1E-636
(signal fault).................................................... 1E-467 DTC: P1632 (Flash code 55) Voltage fault in 5-V
DTC: P0380 (Flash code 66) Glow relay circuit fault power supply 2 ...............................................1E-640
....................................................................... 1E-473 DTC: P1633 (Flash code 55) Voltage fault in 5-V
DTC: P0381 (Flash code 67) Glow plug lamp circuit power supply 3 ...............................................1E-644
fault ................................................................ 1E-478 DTC: P1634 (Flash code 55) Voltage fault in 5-V
DTC: P0487 (Flash code 44) EGR position sensor power supply 4 ...............................................1E-648
fault ................................................................ 1E-484 DTC: P1635 (Flash code 55) Voltage fault in 5-V
DTC: P0488 (Flash code 45) EGR valve control fault power supply 5 ...............................................1E-652
1E-490 DTC: U2104 (Flash code 84) CAN Bus fault..1E-656
DTC: P0522 (Flash code 294) Engine oil pressure DTC: U2106 (Flash code 85) CAN timeout fault
sensor fault (low voltage fault, open circuit, ground .......................................................................1E-661
short) .............................................................. 1E-496 List of Trouble Symptom ...................................1E-666
DTC: P0523 (Flash code 295) Engine oil pressure List of trouble symptom ..................................1E-666
sensor fault (high voltage fault, short to power supply, Engine start failure .........................................1E-667
ground short).................................................. 1E-502 Engine stall.....................................................1E-670
DTC: P0601 (Flash code 53) ROM fault ........ 1E-509 Engine hunting, rough idling...........................1E-673
DTC: P0603 (Flash code 54) EEPROM fault . 1E-511 Engine output shortage ..................................1E-677
Exhaust gas contains a lot of white smoke. ... 1E-681
Exhaust gas contains a lot of black smoke. ... 1E-684
Noise .............................................................. 1E-686
Fuel consumption deteriorates....................... 1E-688
Oil consumption deteriorates. ........................ 1E-691
Special tool........................................................ 1E-693
List of Special Tool......................................... 1E-693
Difference by Each Machine Manufacturer ....... 1E-694
Hitachi Construction Machinery Co., Ltd........ 1E-694
How to Use This Manual

How to use this manual
This manual describes about engine-related trouble diagnosis, and is closely related to the machine trouble diagno-
sis. Always refer to both manuals for the trouble diagnosis.
This manual consists of the following contents. This section “How to use this manual” describes about abbreviations
and instructions to use this manual. Therefore, if you are familiar with manuals, start with Precautions on service
work and Basic procedure of trouble diagnosis.
How to use this manual

• Table of abbreviation
• List of parts according to engine control specifications
• Wiring color code
• How to use wiring diagram
Precautions on service work
Procedure of trouble diagnosis
How to use trouble diagnosis-related tool

• How to use scan tool
• How to use TIS 2000
• How to use injector checker
• How to use flash tool
• How to use breaker box
Engine control system
List of function checks
List of diagnostic trouble codes
List of trouble symptom

Table of abbreviation
Abbreviation Name Meaning and remarks

A/D Analog/Digital Analog/Digital
AP Accelerator Position Accelerator Pedal Position
CAN Controller Area Network Communication system used to communicate between ECM
and the machine control unit
CKP Crankshaft Position Crankshaft (the sensor is installed onto flywheel housing)
position
C/U Control/Unit Abbreviation of control unit
CMP Camshaft Position Camshaft (the sensor is installed onto the rear of cylinder
head) position
DLC Data Link Connector Connector for scan tool (also known as: Checker connector)
EMPS Engine Module Programming System Rewriting of control program in ECM
DMM Digital Multi-Meter Diagnostic tester for electrical equipment system (5-8840-
2691-0)
DTC Diagnostic Trouble Code Self-diagnosis code numbers which indicate trouble condition
ECT Engine Coolant Temperature Engine coolant temperature
ECM Engine Control Module Core of engine control in engine control computer
ECU Electronic Control Unit Computer for various control
EGR Exhaust Gas Recirculation Recirculation system which mixes exhaust gas from engine
with intake air again to lower the combustion temperature
resulting in reduction of NOx.
EMI Electro Magnetic Interference Electro magnetic interference
Exh Exhaust Exhaust
F/B Feed/Back Abbreviation of feedback
FT Fuel Temperature Fuel temperature (the sensor is installed onto supply pump.)
GND Ground Ground/Earth
IAT Intake Air Temperature Intake air temperature
J/C Joint/Connection Connector which connects each harness
MIL Malfunction Indicator Lamp Warning lamp MIL (diagnosis lamp)
PC Pressure Control Pressure control/Common rail pressure
SCV Suction Control Valve Valve which controls fuel flow to common rail and is installed
onto supply pump
PCV Pressure Control Valve Valve which controls fuel flow to common rail and is installed
onto supply pump
PWM Pulse Width Modulation Pulse width modulated wave
QOS Quick On Start Warming-up device
RP Rail Pressure Pressure in common rail
SBF Slow Blow Fuse Slow-blow type fuse which protects circuits of battery, motor,
etc.
SIG Signal Signal
VSS Vehicle Speed Sensor Sensor used to detect vehicle speed to control meters or
engine
W/S Weld/Splice Joint of each harness without connector
List of parts according to engine control specifications
Engine Function
6W 6U 6H 4H 4J
PCV ❍ ❍ Controls the fuel pressure feed of supply pump.
SCV ❍ ❍ ❍ Controls the fuel pressure feed of supply pump.
CMP sensor ❍ ❍ ❍ Detects camshaft position of engine (used for identifying cylinder.)
G sensor ❍ ❍ Detects cam position of supply pump (used for identifying cylinder.)
CKP sensor ❍ ❍ ❍ ❍ ❍ Detects crankshaft position (used for engine control in general.)
About colors of wirings

All harnesses are identified by using different colors of
claddings. The harness for the main circuit in a certain
electrical system is identified by using a single color,
while the harness for the sub circuit uses a color in
stripes. Sizes and colors coding in a wiring diagram are
as follows.
e.g.
Red (stripe color)
Green (base color)
Harness size(0.5mm2)
Name
1. Single color
2. Color stripe
Symbol Color Symbol Color

B Black BR Brown
W White LG Light green
R Red GR Grey
G Green P Pink
Y Yellow SB Sky blue
L Blue V Violet
O Orange
About wiring diagrams
Engine control
module (ECM)
Vehicle speed Engine oil pressure

sensor signal SV SV sensor signal
SV
CKP CKP Engine coolant

Fuel temperature Vcc
HIGH LOW temperature
signal signal sensor signal
sensor signal
108 E-56 107 E-56 106 E-56 19 E-57 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

4
0.75 0.75 0.75

3 H-20 2 H-20 1 H-20 B/Y L/Y W/B
0.75 0.75 0.75 0.75
Y/G B/Y R/B B/Y
0.75 B 2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

Pulse
0.5 0.5 matching
V/W Y box
Engine
2 E-98 1 E-98 coolant
Fuel temperature sensor temperature Engine oil pressure sensor
sensor
3 E-90
CKP sensor A
*
CAN LOW CAN HIGH Engine
0.75 control
R module
(ECM)
Vehicle
speed sensor 37 E-57 18 E-57
4 H-6
A
Meter
Machine
control unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor
TSWG0078
TSWG0120
1. Sections surrounded by long broken lines are used to indicate the units, such as ECM.
2. Sections surrounded by dotted lines are used to classify or differentiate the specifications of machines. Confir-
mation of specifications is needed.
3. Sections surrounded by dotted lines and marked with a symbol (“A” in example) on the upper left are used to
classify different wiring in the specifications of machines. Confirmation of specifications is needed.
4. Sections surrounded by heavy lines are used to differentiate engine harnesses from other harnesses. Heavy
lines indicate engine harnesses, other lines indicate machine harnesses.
How to read trouble diagnosis section
The following illustration is an example for trouble diagnosis section. See this illustration and description.
Description of DTC diagnosis section
The following numbers correspond to those shown in the illustration. They describe each item.
1. DTC:
This indicates trouble code.
2. Flash code
Trouble code indicated by lamp flashing
3. Description of trouble symptom
4. Conditions on system that establish the codes
5. Circuit diagram
Circuit diagram related to trouble code
6. Description of circuit
System circuit principle related to trouble
7. Main trouble symptom
Expected state of engine caused by system trouble
8. Preconditions when DTC is set
Judgment is not performed unless this condition is established.
9. DTC set condition
Condition for fault judgment when preconditions are met
10. Action taken when DTC is set
Behavior of diagnosis lamp, monitor display on the machine and engine control when trouble code is set.
11. Back-up mode
A system operation mode that uses back-up data stored in the ECM memory in disregard of abnormal signal
from sensor, when making fault judgment.
12. Recovery from failure
Description of recovery from failure to normal state
13. Diagnostic aid
Expected trouble causes are listed. They are important information to perform diagnosis.
Be sure to read before trouble diagnosis.
14. Breaker box inspection procedure
There is an appropriate table in diagnostic chart. It describes detailed diagnostic procedure.
Precautions on Service Work

Electrical system • A charging by induction occurs when a person who
wears well-insulated shoes stands near the high-
Use of tools for circuit test electrified object and then he grounds instantly.
If there are no special instructions according to the The same electric charge flows out and that per-
diagnostic procedure, test lights must not be used in son is charged in the high opposite electric charge.
the diagnosis of electric system of powertrain. Use a It is important to be careful in handling or testing
connector test adaptor kit 5-8840-0385-0 when a probe the electronic components because electrostatic
connector is required during the diagnostic procedure. causes damage.
Commercial electrical equipment Caution:

The following guidelines should be followed to pre-
Commercial electrical equipment means that commer-
vent the damage caused by electrostatic dis-
cial electrical components installed to a machine after
charge:
shipment from factory. Be careful that no special con-
sideration for this equipment is taken in the design pro- • Do not touch the ECM connector pins or the
cess of the machine. electronic components soldered on to the cir-
cuit board of the ECM.
Caution: • Package of that part should not be opened until
Connect commercial electrical equipment to the the preparation of the installation of the
circuit whose power supply and ground wires are replacement part is completed.
not related to the electronic control system. • Connect that package to the normal grounding
on the machine before taking out the parts
Commercial electrical equipment may cause malfunc-
from the package.
tion of the electronic control system even if they are
installed properly. They include devices which are not • If handling the parts with moving seats in slid-
connected to the electrical systems on the machine, ing, or sitting down from the standing position,
such as mobile phones or radios. Therefore, in trouble or walking for a certain distance, it is required
diagnosis of powertrain, first check if this commercial to touch the normal grounding before the
electrical equipment is installed, and if so, remove it installation of the parts.
from the machine. If the trouble has not been solved
after the removal, diagnose it in usual procedures.
Welding work on the machine

If performing welding on the machine, remove the bat-
tery in advance. Otherwise, the current during welding
may cause system trouble or damage.
Damage caused by electrostatic discharge

The electronic components used in the electronic con-
trol systems are easy to get damaged, caused by elec-
trostatic discharge because they are designed to
operate in a very low voltage. Some kinds of electronic
components may get damaged by electrostatic in even
less than 100 V which human cannot feel. For refer-
ence sake, the voltage of 4,000 V is needed for human
to feel the flow of electrostatic discharge.
There are several ways for human body to have elec-
trostatic charged. The common way to be charged is
caused by friction or induction.
• For example, a charging by friction is caused when
a person slides on the seat of the machine.
Fuel injection system
Fuel pipe
4 5
TSHK0134
Name
1. Injector pipe
2. Flow damper
3. Common rail
4. Common rail pressure sensor
5. Pressure limiter
• Do not reuse the high-pressure pipe and injector

pipe of the fuel system. Replace with new one if it
is removed.
• Never replace the pressure limiter, fuel tempera-
ture sensor, flow damper alone. If faulty, replace
the common rail assembly and all the fuel pipes.
Procedure of Trouble Diagnosis

About trouble diagnosis
The following diagnostic procedure is extremely important to solve the problems of all electric/electronic (E/E) sys-
tems. Failure to perform this procedure may require unnecessary repair. Read carefully this procedure to under-
stand, and then perform trouble diagnosis.
In addition, use the effective function or a scan tool to perform trouble diagnosis and system check.
ECM control
DTC
Sensor output
Data Link Connector
Read DTC Actuator Test
V
V
RPM
RPM
Snapshot V
V
%
TSWG0121
Trouble diagnostic procedure
Step 1 Confirm the user’s complaint
• Organize the trouble conditions using a check list.
Step 2 Perform pre-inspection

• Perform an overall visual check.
• Confirm the service history in the past.
• Detect faulty such as noise, abnormal smell, etc.
• Collect the diagnostic trouble code (DTC) information for effective repair.
• Check for faults by comparing with the specified value.
Step 3 Check service information

• Check service bulletins for the market.
Step 4 Check according to each DTC

• Check the items indicated by the diagnostic trouble code (DTC)
Step 5 Perform fault inspection for each symptom

• Check the items not indicated by the diagnostic trouble code (DTC).
Information:
Control System
Engine Control About types of system trouble diagnosis
(Electronic control fuel injection system (Common rail type))
Table of Contents System diagnostic method is a standardized method to
repair all the electric/electronic (E/E) systems. The
Engine Control System . . . . . . . . . . . . . . . . . . . 10D-4 DTC: P0238 (Flush code 32). . . . . . . . . . . . 10D-230
Precautions on service work . . . . . . . . . . . . . . 10D-4 DTC: P0335 (Flush code 15). . . . . . . . . . . . 10D-235
Description of function and operation . . . . . . . 10D-7 DTC: P0336 (Flush code 15). . . . . . . . . . . . 10D-240
1 Engine component location diagram. . . . . . . 10D-16 DTC: P0340 (Flush code 14). . . . . . . . . . . . 10D-244
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . 10D-28
Procedure of trouble diagnosis . . . . . . . . . . . 10D-47
DTC: P0107 (Flush code 71) . . . . . . . . . . . 10D-143
Interview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10D-49
DTC: P0341 (Flush code 14). . . . . . . . . . . . 10D-249
DTC: P0487 (Flush code 44). . . . . . . . . . . . 10D-262
DTC: P0488 (Flush code 45). . . . . . . . . . . . 10D-267
faults in E/E system often occur in the following stages,
DTC: P0108 (Flush code 71) . . . . . . . . . . . 10D-148
different from general machine fault.
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . 10D-51 DTC: P0522 ((Flush code294). . . . . . . . . . . . 10D-262
Trouble diagnosis with scan tool . . . . . . . . . . . 10D-56 DTC: P0523 ((Flush code294). . . . . . . . . . . . 10D-267
DTC: P0112 (Flush code 22). . . . . . . . . . . .
Precautions on handling Tech 2 . . . . . . . . . . 10D-60 10D-153 DTC: P0601 (Flush code 53). . . . . . . . . . . . 10D-272
How to use Tech 2. . . . . . . . . . . . . . . . . . . . . 10D-62 DTC: P0603 (Flush code 54). . . . . . . . . . . . 10D-273
DTC: P0113 (Flush code 22). . . . . . . . . . . . 10D-158
How to use injector checker . . . . . . . . . . . . . 10D-87 DTC: P0606 (Flush code 51/52) . . . . . . . . . 10D-274
DTC: P0117 (Flush code 23). . . . . . . . . . . . 10D-164
List of function checks. . . . . . . . . . . . . . . . . . 10D-88
OBD system check. . . . . . . . . . . . . . . . . . . . . . 10D-89
Diagnosis lamp illumination circuit system check10D-
DTC: P0611 (Flush code 34) . . . . . . . . . . . . 10D-275
DTC: P0612 (Flush code 34). . . . . . . . . . . . 10D-278
DTC: P0615 (Flush code 19). . . . . . . . . . . . 10D-281
1. Early stage of fault;
91 DTC: P0650 (Flush code 77). . . . . . . . . . . . 10D-286
Diagnosis lamp blinking circuit system check 10D-93
Scan tool power supply circuit system check 10D-96
Scan tool communication circuit system check. 10D-
DTC: P1093 (Flush code 227). . . . . . . . . . . 10D-291
DTC: P1094 (Flush code 226). . . . . . . . . . . 10D-299
DTC: P1095 (Flush code 225). . . . . . . . . . . 10D-306
• As the fault occurs for a short period and singly,
a customer often does not notice and miss it. In
98 DTC: P1112 (Flush
( code 542) . . . . . . . . . . . 10D-314
Starting circuit system check. . . . . . . . . . . . 10D-101 DTC: P1113 ((Flush code 158). . . . . . . . . . . 10D-322 2
Starting system check . . . . . . . . . . . . . . . . . 10D-106 DTC: P1173 (Flush code 542) . . . . . . . . . . . 10D-314
Fuel system check . . . . . . . . . . . . . . . . . . . 10D-109 DTC: P1261 (Flush code 158). . . . . . . . . . . 10D-322
List of trouble symptom . . . . . . . . . . . . . . . . . 10D-397
Intake system check . . . . . . . . . . . . . . . . . . 10D-111
Exhaust system check . . . . . . . . . . . . . . . . 10D-112
EGR control system check . . . . . . . . . . . . . 10D-113
DTC: P1262 (Flush code 159). . . . . . . . . . . 10D-330
DTC: P1271 (Flush code 24). . . . . . . . . . . . 10D-338
Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . 10D-401
DTC: P1277 (Flush code 24). . . . . . . . . . . . 10D-343
this stage, customer’s complaint is indefinite
and it is impossible to reproduce the trouble.
QOS system check . . . . . . . . . . . . . . . . . . . 10D-116 DTC: P1278 (Flush code 24). . . . . . . . . . . . 10D-348
List of diagnostic trouble code . . . . . . . . . . . . 10D-120Engine hunting, rough idling . . . . . . . . . . . . 10D-404
DTC: P1282 (Flush code 24). . . . . . . . . . . . 10D-353
DTC: P0088 (Flush code 118). . . . . . . . . . . 10D-129 DTC: P1283 (Flush code 24). . . . . . . . . . . . 10D-358
DTC: P0089 (Flush code 151) . . . . . . . . . . 10D-133 Engine output shortage . . . . . . . . . . . . . . . . 10D-408
DTC: P128 5 (Flush code 16). . . . . . . . . . . . 10D-363
DTC: P0091/P1291 (Flush code 247/248) . 10D-138
DTC: P0092 (Flush code 71) . . . . . . . . . . . 10D-140
DTC: P0107 (Flush code 71) . . . . . . . . . . . 10D-143
DTC: P128 5 (Flush code 416). . . . . . . . . . . 10D-367
DTC: P129 0 (Flush code 36). . . . . . . . . . . . 10D-373
DTC: P1345 (Flush code 16). . . . . . . . . . . . 10D-363
However, the engine control module (ECM)
may store the fault.
DTC: P0108 (Flush code 71) . . . . . . . . . . . 10D-148 DTC: P1625 (Flush code 416). . . . . . . . . . . 10D-367
DTC: P0112 (Flush code 22). . . . . . . . . . . . 10D-153 DTC: P1630 (Flush code 36). . . . . . . . . . . . 10D-373
DTC: P0118 (Flush code 23). . . . . . . . . . . . 10D-169
DTC: P0182 (Flush code 211). . . . . . . . . . . 10D-174
DTC: P0183 (Flush code 211). . . . . . . . . . . 10D-178
DTC: P1633 (Flush code 55). . . . . . . . . . . . 10D-380
DTC: P1634 (Flush code 55). . . . . . . . . . . . 10D-383
DTC: P1635 (Flush code 55). . . . . . . . . . . . 10D-386
=Past fault (history trouble)
DTC: P0192 (Flush code 245) . . . . . . . . . . 10D-183 DTC: U2104 (Flush code 84). . . . . . . . . . . . 10D-389
2. Middle stage of fault;

DTC: P0193 (Flush code 245) . . . . . . . . . . 10D-188 DTC: U2106 (Flush code 85). . . . . . . . . . . . 10D-393
DTC: P0201 (Flush code 271) . . . . . . . . . . 10D-193 List of trouble symptom . . . . . . . . . . . . . . . . . 10D-397
DTC: P0202 (Flush code 272) . . . . . . . . . . 10D-198 Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . 10D-401
DTC: P0203 (Flush code 273) . . . . . . . . . . 10D-203 Engine hunting, rough idling . . . . . . . . . . . . 10D-404
DTC: P0204 (Flush code 274) . . . . . . . . . . 10D-208 Engine output shortage . . . . . . . . . . . . . . . . 10D-408
DTC: P0205 (Flush code 275) . . . . . . . . . . 10D-213
DTC: P0206 (Flush code 276) . . . . . . . . . . 10D-218
DTC: P0219 (Flush code 543) . . . . . . . . . . 10D-223
Exhaust gas contains a lot of white smoke.. 10D-411
Exhaust gas contains a lot of black smoke.. 10D-414
Programming . . . . . . . . . . . . . . . . . . . . . . . . . 10D-416
• The fault occurs for a short period and singly,
but repeats intermittently and definitely occurs
DTC: P0237 (Flush code 32) . . . . . . . . . . . 10D-225 Rewriting of ECM (On-board)
TSWG0156
Name under a specific condition. A customer’s com-

1. Diagnosis for each DTC plaint (contents of the fault) is clear but descrip-
2. List of trouble symptom tion of condition of the fault is not clear.
Therefore, it is possible to reproduce the trou-
ble if a mechanic could figure out the condi-
tions.
=Intermittent trouble (intermittent)
3. Stage that fault is real;
• The fault occurs on a steady basis and a cus-
tomer’s complaint is realistic and clear.
Therefore, it is possible for a mechanic to
reproduce the fault. However, sometimes there
are multiple causes.
=Current fault (present trouble)
Interview • Extra repair steps are caused if the trouble condi-
tion is not correctly reported to a mechanic in
Interview charge.
1. Comprehend the contents of a customer’s com- • The check list helps to diagnose, repair, and
plaint using “Check list (engine control system)”. recheck after repair work in the maintenance shop.
Note:
Do not interview blindly. Interview about the trouble
presumed by symptoms (cases).
2. Evaluate the trouble information correctly.

Figure out specifically based on 5W1H.
Example: The temperature is low, at the time of
starting, constantly, in the vicinity of the engine
portion, metallic noise, etc.
Points for interview
• What Trouble symptom

• When Date, time, frequency of
occurrence
• Where Road condition
• In what condition Running condition, operat-
ing condition, weather
• How Feeling about symptom
Check list for engine control system

It is necessary to confirm “Trouble symptom” and “Data
of occurrence of a trouble” based on check list (engine
control system) on receiving the machine from a cus-
tomer at a service shop.
TSWG0155
TSWG0160
Name
1. Trouble symptom
2. Frequency of trouble occurrence / trouble condi-
tions
Because:
• It may be impossible to reproduce the trouble
symptom at a service shop.
• All of complaints from customers do not always
mean troubles.
TSWG0155
Pre-inspection Trouble diagnosis
Visual inspection of engine compartment Basic knowledge for required tools
Visual inspection of engine compartment should be Important:
carefully when performing the diagnostic procedure. If performing the diagnostic procedure, no basic
This inspection can often solve the trouble with no extra knowledge on this powertrain may lead to faulty
steps. If performing visual inspection, follow the guide- diagnosis or damage to powertrain components. If
line below. you do not have basic knowledge, do not perform
• Check all the air hoses etc. for punch hole, cut, dis- the diagnosis of the trouble relating to powertrain.
connection or improper routing. Basic understanding on hand tools, such as scan
tools, is required to utilize service manual effec-
• Inspect the hoses hidden behind other compo-
tively.
nents.
• Check if all the harnesses of the engine compart- About on-board diagnosis test
ment are properly connected, if there are any burn-
out parts or worn parts, if harnesses are pinched, if Types of trouble diagnosis results are the following.
there are any contacts with sharp edges, or an 1. History trouble
exhaust manifold or pipes in high temperature, etc. Trouble codes which occurred under the following
conditions are called “History trouble”.
Machine maintenance result check • Diagnostic test was completed at previous igni-
If the maintenance of the machine is not properly per- tion cycle.
formed, the diagnosis lamp comes on. Clogging in oil • Diagnosis test has accepted at current ignition
filter or fuel filter caused by insufficient oil change or cycle.
improper oil viscosity and deposit in crankcase may • Faults found by the diagnostic test do not cur-
cause troubles on the machine, which were not found rently exist.
before on-board diagnosis (OBD) system check.
2. Present trouble
Though improper maintenance of the machine is not
Trouble codes which occurred under the following
classified as “The trouble caused by other than a
conditions are called “Present trouble”.
machine”, a maintenance schedule should be more
strictly followed because of high sensitivity of the on- • Diagnostic test was completed at previous igni-
board diagnosis (OBD) system check. tion cycle.
• The faults detected by the diagnostic test cur-
Non-OEM parts rently exist.
All the on-board diagnosis system checks are adjusted • The faults exist at current ignition cycle.
to be operated by genuine parts. Therefore, if a com-
mercial general sensor or switch is installed, the diag- Description of terms
nosis lamp comes on due to faulty diagnosis. Diagnostic trouble code (DTC)
If commercial electronic devices, such as mobile Every time turning the key switch to ON, the ECM per-
phone, stereo, antitheft device, etc. are installed and forms self-test of most wiring and components and
their installation is not proper, EMI (electromagnetic stores the detected faults in memory. For some DTCs,
interference) may be discharged to the control system. it also performs the back-up control. If the fault which
That leads to the generation of fault sensor information affects operation occurs, the diagnosis lamp comes on
and the diagnosis lamp comes on. When performing to notify an operator.
trouble diagnosis, turn the power of all commercial
parts to “OFF” or remove those parts, and check for Ignition cycle
faults again. Ignition cycle is defined as Key ON, Run and Key OFF
so that the machine can be operated under the speci-
Information: fied diagnostic standard.
Fault in related system Diagnosis lamp

Basically, the diagnosis lamp comes on when the fault
Many on-board diagnosis (OBD) system checks enter occurs in electronic control, such as engine control
the back-up operating mode by instruction from engine module (ECM), and a DTC (diagnostic trouble code) is
control module (ECM) when the ECM detects the fault detected.
in related systems or components. In the back-up oper-
ating mode, they lower output to protect the machine. Data link connector (DLC)
The data link connector is communication device with
control unit. The DLC is also used to connect a scan
tool. General use of scan tool is described below.
• Identification of stored DTC
• Reading of serial data
Note: • Lamp, relay control
The location of DLC and existence of DLC vary • Magnetic valve
depending on each machine. Refer to the machine’s
• Diagnosis lamp
manual.
ECM OFF
How to read DTC
The power of ECM is cut off 10 seconds after the key
switch is turned to OFF, and then it will be ECM OFF How to read DTC by diagnosis lamp
condition. The diagnosis lamp blinks to indicate the current and
history trouble codes (DTCs) stored in ECM by con-
Operation of comprehensive diagnosis for necting the diagnosis switch.
monitors of components
Note:
It is necessary to comprehensively diagnose compo-
Refer to the machine’s manual for the locations of diag-
nents for the proper operation of the engine.
nosis lamp.
Input components:
• Turn the key switch to ON and make sure the diag-
Input components are confirmed to check if there are nosis lamp illuminates. (Bulb check)
open circuit and the values exceed the range.
• Turn the key switch to ON, and the engine OFF.
Though the following does not include all input compo-
nents, these sensors are included. • Connect the diagnosis switch (connector). (If the
machine has no diagnostic switch, short the DLC
• Crankshaft position (CKP) sensor
No. 1 with No. 4 or No. 5.)
• Camshaft position (CMP) sensor
• Read the blinking pattern of the diagnosis lamp.
• Engine coolant temperature (ECT) sensor
• Judge the contents of DTC by DTC table.
• Vehicle speed sensor If a scan tool has been connected, it can be read using
• Boost pressure sensor the tool.
• Common rail pressure sensor
• Accelerator position (AP) sensor
Indication with no DTC stored
The code “1”, which indicates starting of code display,
Output components: is repeatedly displayed.
Output components are diagnosed if their responses to
commands from control units are relevant. Check Indication with DTC stored
whether there are open circuit and the values exceed Stored trouble code is displayed three times. If more
the range. than one trouble code are stored, they are displayed in
Though the following does not include all the output the ascending order for three times each. After taking a
components to be confirmed, these circuits are round, codes are repeatedly displayed in the ascending
included. order. This will last as long as the diagnosis connector
• Suction control valve (SCV) is connected.
At code [23]
t1=approx. 0.3 sec.

ON t2=approx. 0.6 sec.
t3=approx. 1.2 sec.
t4=approx. 2.4 sec.
Goes off
Tens digit Units digit
At code [413]
ON
Goes off
Hundreds digit Tens digit Units digit

About DTC indicated by blinking of diagnosis If the trouble is not detected
lamp In this case, the machine is judged as it operates prop-
While the engine stops, both the current and past DTCs erly. The condition explained by the customer may be
are displayed. the normal condition. Confirm the customer’s complaint
While the engine is operated, the lamp illuminates only comparing with the condition of the machine to that of
if the current DTC occurs. another machine. That condition may mean an intermit-
tent trouble. Confirm the complaint in the situation the
How to read DTC by trouble display monitor customer explains before returning the machine to the
customer.
When a DTC occurs, it is displayed on trouble display
monitor on the machine. 1. Confirm the complaint again.
If the complaint can not be fully detected or identi-
How to read DTC by a scan tool fied, the machine must be diagnosed again. Con-
firm the complaint one more time. The complaint
DTC can be read using a scan tool. may be an intermittent trouble as defined in “If
there is intermittent”, but it may also be possible
Note:
that the machine is normal.
Refer to 1E-34, “Diagnostic procedure, Tech2, How to
Use Trouble Diagnosis-Related Tool” for work proce- 2. Repair and confirm.
dure. If the problem is confirmed, repair it. Confirm that
the machine operates properly and the symptoms
If the DTC (diagnostic trouble code) is stored are corrected. This includes test on the machine or
other procedures to confirm that the trouble is
Perform service correctly according to the specified solved under following conditions:
DTC chart.
• Confirm by testing in the situation that the cus-
tomer described.
If there is no DTC
• If DTC is diagnosed, reproduce the situation
Select symptom from the diagnostic chart according to found while the DTC is set, and confirm the
symptom. Complete the service following diagnostic repair by checking a scan tool data.
procedure. You may also perform inspection by refer-
ring function diagnosis.
If there is no applicable symptom

1. Confirm the complaint in detail.
2. Create diagnostic plan.
3. Use wiring diagram and principle of operation.
Ask for technical support when repair history is avail-
able for similar case. Connect technician’s knowledge
with the effective usage of available service informa-
tion.
If there is intermittent (intermittent trouble)

The trouble situation not occurring constantly is called
intermittent (intermittent trouble). Perform the following
steps to solve the intermittent trouble.
1. Check the DTC information and data display.
2. Evaluate symptom and situation explained by the
customer.
3. Check the circuits or the electric system compo-
nents using check sheet or other methods.
Confirmation after repair About confirmation of machine repair
Confirmation of machine repair It is effective for confirmation of machine repair to use
on-board diagnosis (OBD) system check. Mechanic
If an electronic control system is repaired, it is neces-
should perform the following steps to diagnose the
sary to confirm that repair is properly performed after
machine after repair.
the repair work. If this confirmation is not properly per-
formed, it may happen that the diagnosis lamp comes 1. Review and record the DTC (diagnostic trouble
on again or a trouble in operability occurs in the course code) or scan tool data used in diagnosis.
of delivering the machine to the customer. Especially 2. Clear the DTC.
as for intermittent (trouble), it is needed to reproduce 3. Operate the machine based on scan tool data.
and confirm the situation according to the customer’s
4. Confirm the DTC status information of specified
complaint.
DTC used in diagnosis until the diagnostic test
relating that DTC is performed by control unit.
In the case of confirmation of repair by on-board diag-
nosis (OBD) system check, performing these steps is
extremely important. Failure to perform these steps
may require unnecessary repair.
List of final check items
No. Item Purpose Method

1 Check of DTC Confirm the DTC display after Clear previous DTC. To gain a test environment, warm-
repair. up sufficiently with idling and raise the engine speed to
“No Load Max.” to race.
2 Confirmation of idle To check whether the idling con- Check whether the idle speed after warm-up is stable
speed after the trol is normal or not. under no load condition. If the trouble is detected, refer
engine is warmed- to “Unstable idling” in symptom diagnosis.
up.
3 Check the scan Check the engine control and Monitor the scan tool data list and use a typical data
tool data list. communication status for faults at sheet to perform the check.
standard condition. Confirm the typical data of scan tool data list.
4 Confirmation of To check whether the starting Confirm that after the engine is warmed up. Confirm
ability of restarting control is normal. that the engine starts after less than 5 second of crank-
ing time and becomes stable.
5 Confirmation of If an electric wave transmitting Check if idling engine speed changes due to “ON” and
powerful electric equipment such as transceiver is “OFF” of an electric wave transmitter such as trans-
wave transmitter. additionally installed, confirm ceiver. If a fault is found, inform a customer of neces-
whether interfering electric wave sity to change the location and output of an electric
is consequently transmitted or wave transmitter.
not.
Confirmation of powerful electric wave transmitter; if Caution:

faults are found in these items, inform a customer of If confirming repair using on-board diagnosis sys-
the following check items as required. tem check, perform the following steps. If not fol-
• An antenna should be installed as far away as pos- lowing these steps, unnecessary repair may be
sible from the electrical systems on the machine needed.
such as control unit/sensors. • Review and record the scan tool data related to
• Antenna cords should be installed at least 20 cm DTC which is diagnosed.
(7.8 in) away from the electrical systems on the • Clear the DTC.
machine such as control units/sensors. • Operate the machine while checking the rele-
• Do not put the antenna cords and other wire vant scan tool data.
together. Keep the antenna cords as far away from
other wire as possible.
• When installing an additional equipment, follow its
installation manual to install it securely.
• Do not install mobile communication equipment
with high output.
How to clear DTC Clear with ECM (intermittent trouble)
Clear of DTC The DTC stored in ECM will be cleared if the same one
is not valid within 20 ignition cycles.
The DTC, which have been stored in the engine control
module (ECM) upon trouble occurrence, will not be
erased even if the faulty parts are repaired, unless it is
compulsory cleared in the following procedure.
Clear with a scan tool

If a scan tool (Tech2 or scan tool with KW communica-
tion) has been connected, it can be cleared by clear
operation of the scan tool (Tech2 or scan tool with KW
communication).
If a scan tool with CAN communication has been con-
nected, clear with the memory clear switch.
Clear with memory clear switch

1. Turn the key switch to ON.
2. Turn the diagnosis switch to ON.
3. Turn the memory clear switch to ON.
4. Leave as it is ON for 3 seconds.
5. Turn the memory clear switch to OFF.
6. Turn the diagnosis switch to OFF.
7. Turn the key switch to OFF.
8. Leave as it is for 10 seconds.
10. Turn the diagnosis switch to ON.
11. Make sure that memory is cleared.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
TSWG0023
Note:
• Refer to the machine’s manual for the locations of
memory clear switch and diagnosis switch.
• Perform the same procedure to clear memory
regardless of forms of switches (switches, connec-
tors). (ON = Connection, OFF = Disconnection)
Trouble diagnosis with scan tool Isuzu scan tool (Tech2) and the scan tools with KW
communication can display both the physical value and
About scan tool voltage value.
There are scan tools for Hitachi Construction In some diagnostic charts, both the voltage value and
Machinery and the scan tool (Tech2) for Isuzu, and physical value may be shown. Refer to the voltage
they have different display method respectively. value for Tech2 and the scan tools with KW communi-
The scan tools for Hitachi Construction Machinery with cation or the physical value for the scan tools with CAN
CAN communication display only the physical value in communication.
data parameters.
Value
TSWG0182
TSWG0185 Name
1. Tech2 and scan tool with KW communication
2. Scan tool with CAN communication
About scan tool display

ECM has different displays; KW and CAN. For data display, refer to appropriate section for Hitachi Construction
Machinery.
Tech2, KW display CAN display
Engine Model (EEPROM) Engine Model
Engine Serial Number (EEPROM) Engine Serial Number
ECM Parts Number (EEPROM) ECM Parts Number
Software ID (EEPROM) Software Identification
Q Resistance (EEPROM) Q adjustment data
QR Code (EEPROM) QR code
Starter Switch (On) —
Starter Switch (ST) —
EGR BLDC Position 1 —
Glow Relay Switch —
— Glow Signal
Accelerator Sensor 1 Act Accel position
System Voltage —
Main Relay Voltage —
— Battery Voltage
Tech2, KW display CAN display

Intake Air Temperature Sensor —
Fuel Temperature Sensor —
Engine Coolant Temperature Sensor —
Idle Up Volume Sensor —
Barometric Pressure Sensor —
Differential Fuel Rail Pressure —
Differential EGR Valve Position Sensor —
Engine Speed Act. Engine Speed
Desired Engine Speed Request Engine Speed
Intake Air Temperature Intake Air Temperature
— Boost pressure
— Boost Temperature
Engine Coolant Temperature Coolant Temperature
Fuel Temperature Fuel Temperature
Barometric Pressure Barometric Pressure
Engine oil pressure Engine Oil Pressure
— Fuel Flow
— Engine Torque
— Trip used fuel
— Total used fuel
Differential EGR Position (BLDC Motor) —
SCV Duty —
EGR BLDC Motor Duty —
EGR DC Motor Duty —
SCV F/B —
Desired Idle Speed —
Common Rail Pressure F/B Mode —
Engine Mode —
Target Fuel Flow —
Main Fuel Injection Timing —
Pre-fuel Injection Amount —
Main Fuel Injection Amount —
About scan tool (Tech2)
This is an useful tool to diagnose the electric faults and
the system check of the engine control system. The
Tech2 is small and light tester. It can communicate with
each control unit to perform various types of diagnosis
and test by connecting it to DLC equipped to the
machine using Tech2 adapter.
ECM control
DTC
Sensor output
Data Link Connector
Read DTC Actuator Test
V
V
RPM
RPM
Snapshot V
V
%
TSWG0121
Function of Tech2 • The trigger type allows to record the data of the
time when DTC is displayed.
Data display
• The stored data can be replayed with a domestic
This displays conditions recognized and controlled by
power supply.
ECM at each items.
The values of display items is described in typical data Programming
of Tech2 data list.
The contents of display items describe about data. Confirm the data history before replacement of ECM.
(Data confirmation) Then, upload the data to the
Tech2. After replacement of ECM, download data from
Tech2 to new ECM.
Actuator test
V Perform each test to check the operation or function of
V appropriate parts for faults.
RPM When giving instruction to ECM from test screen, set
RPM the select switch of the Tech2 adapter to “2” position.
V
V Caution:
% Each test may not performed if the machine, engine
MPa
operation status, coolant temperature, vehicle
speed, switch status, gear position, etc. does not
meet conditions or if DTC is detected.
TSWG0098
This menu can be used to display the current data.

The display synchronizes with the status of the
machine or equipment.
• If the data display menu cannot be selected:
Trouble occurs on the cable between ECM and
DLC.
The position of select switch on Tech2 adapter is
wrong.
• If the abnormal fixed value is displayed:
[Example] The data display value of engine speed,
each sensor, etc. is fixed and different from actual
one. Move the connector or harness by hand. If the
display changes from fix to release, connection of
the connector is faulty, pin tip length is uneven, or
open or short circuit exists in the harness where
you have moved. Therefore, repair is necessary.
• When asterisk mark (*) is displayed in place of
numeric display;
The Tech2 software has problem.
If asterisk mark (*) is found on any of the data,
PCMCIA card must be version-upgraded.
Snapshot
To find the cause of trouble, perform this snapshot to
review the data.
• The snapshot can record the data list menu and
plot a graph.
• Utilizing this mode, reproduce and record the con-
ditions claimed by the customer to identify the data
fault.
How to Use Trouble Diagnosis-Related Tool

Tech2
Components of Tech2
1 5
3 4
TSWG0148
Name
1. PCMCIA card 4. DLC cable
2. SAE 16/19 adapter 5. Tech2
3. Power cable
Each part of Tech2
Name
1. Softkeys 10. Fastening bar of VCI module
2. Selection keys (Arrow keys) 11. Connector of DLC cable connection
3. Action keys (YES, NO, ENTER, EXIT) 12. Connector for AC adapter connection
4. Function keys (F0 — F9) 13. PCMCIA card insertion slot with cover
5. Help key (?) 14. PCMCIA card release button
6. Control keys (PWR / SHIFT) 15. Connector for external communication (RS-232
7. Wide stand port)
8. Display area (LCD) 16. Connector for external communication (RS-485
9. Machine communication interface (VCI) module port)
Softkeys Selection keys (Arrow keys)

While operating the Tech2, selection boxes appear on They are used to select the menu or switch the display
the upper part of the screen. The softkeys correspond on the screen of Tech2. Selected part is highlighted in
the selection boxes. They cannot be used unless the the screen.
selection boxes are displayed.
Action keys (YES, NO, ENTER, EXIT)
They are used to execute the operation of Tech2,
respond to instruction/question, and switch/move to
each menu screen.
Function keys (F0 — F9) Precautions on handling Tech2
They are used to execute a menu function in the
Ventilation
screen. These keys also correspond to F numbers,
such as “F0”, when they are displayed on the menu If performing inspection and test with engine running in
screen. badly ventilated area, such as garage, ventilate suffi-
ciently. In badly ventilated area, poisoning may occur
Help key (?) due to inhaling colorless, odorless carbon monoxide
Explanation of Tech2 function, which is being used at included exhaust gas.
the time when the key is pressed, is displayed
Control keys (PWR / SHIFT) Handling
The PWR key turns on/off the power to the Tech2. The • The Tech2 is “precision electronic device”. Handle
SHIFT key is used to adjust the screen contract. When with extreme care.
the SHIFT key is active, the orange LED illuminates. In • Operating voltage of Tech2 is DC 12 V. Do not
this case, all the keys except selection keys and func- energize 24 V to it.
tions are locked. When the power is on, the green LED
illuminates.
Wide stand
Use this as a stand. The stand opens angle of 0 —
180°.
Display area (LCD)
This is liquid crystal display (LCD) with contrast adjust-
ing function. It displays ECM information and various
instructions.
Machine communication interface (VCI) module
This is a module to communicate between the machine
and Tech2.
Fastening bar of VCI module
The bar is used to install/fasten/remove the VCI.
Connector of DLC cable connection
This is used to connect the Tech2 to the machine. Con-
TSWG0111
nect the DLC cable.
• Do not have an impact on it by dropping. It causes
Connector for AC adapter connection internal faults even no damage on appearance.
This is used to connect the attached AC adapter when
using Tech2 with other than the machine.
PCMCIA card insertion slot with cover
Open the cover when inserting the PCMCIA card into
Tech2. Insert the PCMCIA card with the cover opened.
Never insert/remove the PCMCIA card when the Tech2
is powered on.
PCMCIA card release button
This is used to remove the PCMCIA card from Tech2.
Press the button to remove the PCMCIA card. Never
remove the PCMCIA card when the Tech2 is powered
on.
Connector for external communication (RS-232
port)
This is used to connect the Tech2 to a computer.
Connector for external communication (RS-485
port) TSWG0112
This is a connector for phone line connection, however • Be sure to turn off the power of Tech2 when install-
it is not currently used. Do not connect the phone line ing/removing the PCMCIA card. Avoid repetition of
etc. to this connector. installing/removing the card as possible. Other-
wise, the card may be deteriorated.
• Before turning on the Tech2, make sure that the
cables and adapters are connected securely.
• Do not disconnect the cables and adapters con-
nected to Tech2 while the key switch is ON or the
engine is starting.
• Do not connect the phone jack to communication
port on the side of Tech2.
TSWG0115
• Avoid using and storing it in a place with extreme

high or low temperature. Especially in summer, do
not leave it in the machine exposed to direct sun-
light.
TSWG0113
• Avoid using and storing it in dusty area. When not

using it, always put it in its case to prevent the
adapter from getting dust.
TSWG0116
• Avoid using and storing it in a place that it may

contact water or chemicals. When cleaning, use
cloth with mild detergent, not highly-volatile solvent
TSWG0114 such as thinner, and wipe out using dry cloth. Its
• Avoid using and storing it in a place with rapid display is easy to get dirty, clean periodically using
changes of temperature. If bringing it from cold antistatic cloth.
outside into warm indoor suddenly, dew condensa-
tion may occur resulting in malfunction or trouble.
Power supply
About power supply
The power supply method for the Tech2 varies depend-
ing on the voltage of the machine, shape of DLC and
the situation in which the unit is used. Therefore the
user will have to gain good understanding of the rele-
vant connecting procedure.
Notice that machine data and DTC will not be able to
be checked if the connection is not established in
accordance with the power supply of the machine.
Note:
Use of the external power (AC power) does not allow to
utilize the applications.
TSWG0117
Connection of power
TSWG0162
Name
1. Battery cable 2. Power socket cable (AC/DC adapter)
Battery cable
This cable should be used, in the case where no power
is supplied even when the Tech2 is connected to the
machine through the machine DLC cable, or where the
machine works with a higher voltage than the operating
voltage of the unit. When connecting the cable, pay
heed to the polarities of the clamps. (The black clip of
the cable is to be connected to the negative terminal of
the battery and the red clip to the positive terminal.)
Caution:
In the case of a 24-V machine, connect to battery
on the body ground side to take out 12 V.
How to connect Tech2
1. Insert the PCMCIA Card with the latest version of
ISUZU system into the Tech2.
2. Connect the SAE 16/19 adapter to the DLC cable.
3. Connect the DLC cable to the Tech2.
4. Make sure that the key switch is OFF.
5. Connect the SAE 16/19 adapter of Tech2 to the
machine DLC.
Caution:
Connecting method varies depending on each
machine. Refer to the machine’s manual. The fol-
lowing description is for the machine with DLC.
TSWG0141
Power socket cable (AC/DC adapter)

This is used to check the captured data by operating
Tech2 away from the machine.
Caution:
Be sure to use the power socket cable adapted to
local standards. Otherwise, it may result in failure
of Tech2 or power socket cable due to different
voltage and current depending on regions.
Check items before use

VCI
Check to see whether the VCI module is securely TSWG0118
inserted and whether the fastening latch bar of the VCI
module is located on the left-hand end.
Attach the DLC cable and fasten it by tightening the two
lock screws.
PCMCIA Card
Check to see whether the slot (upper side) has this
card inserted with its “Tech2” label side up.
Caution:
If the card is not inserted properly and the unit is
switched on, “NO PCMCIA CARD INSERTED” will
appear. If that is the case, turn off the power and
redo the insertion of the PCMCIA Card.
Connection
Check to see whether the DLC cable is fitted with an
adapter compatible with the machine.
TSHK0144
Note: 6. Turn the ignition switch to ON and press the
Before connecting the cable to the machine, verify that “PWR” key of the Tech2.
the key switch is in the “OFF” position.
7. Check the display of the Tech2.
Caution:
In the case of a 24-V machine, connect to battery
on the body ground side to take out 12 V.
Note:
• If the LED fails to come on, it means a malfunction
of the LED, not a malfunction of the SHIFT key.
• Absence of sound means a malfunction of the
Sound Transducer*1, but the unit can be used as
is, without any problem.
*1. Sound Transducer: The sound is intended to
indicate the completion of a data setup or an error
in a setup.
TSWG0110
Caution:
Be sure to turn off the power of Tech2 when install-
ing/removing the PCMCIA card.
Start-up
The Tech2 is designed to automatically conduct a self-
function test every time it is started. Immediately after
the unit has been switched on, the “SYSTEM INITIAL-
IZING” message will appear. During this period, POST TSGW0085
(Power-On Self Test) is carried out, and if the test ends Pass: Normal, Fail: Abnormal
normally, a sound will be issued at the completion of
the test. Simultaneously, the LED of the SHIFT key will Note:
momentarily come on. This is also meant to check the Only for UART, SCI, RTC, and CLKMEM in particular,
normality of the LED. the test result may appear as “Fail” without this mean-
ing any trouble. For “Fail” above, refer to 1E-46, “Tool
option menu, Tech2, How to Use Trouble Diagnosis-
Related Tool”.
IRAM: Internal RAM

ERAM: External RAM
UART: Universal Asynchronous Receiver and Trans-
mitter
MCU: MC68332 Microcontroller
QSPI: Queued Serial Peripheral Interface
S Y S T E M IN IT IA L IZ IN G SCI: Serial Communication Interface
TPU: Time Processor Unit
RTC: Real-Time Clock
CLKMEM: Clock Memory
KEYPAD: Keypad
TSWG0084
Display of POST results:

If the test ends normally, “Pass” will appear and one
short sound will be heard.
If the test ends abnormally, “Fail” will appear and three
short sounds will be heard.
Main Menu • Data Display: Shows the input/output data to/from
the machine controller under test. Since the dis-
If all the functions are normal after the Tech2 has been
played data varies from a system to another, and
switched on, the Start Up screen will open, displaying
besides, most of the items do not have their guid-
the Version No. and the applicable model year, stored
ance standard values installed, it is necessary to
on the PCMCIA card, to allow the user to verify the
information. After the Start Up screen has opened, first check what the displayed data means.
pressing the [ENTER] key will cause the “Main Menu” • Snapshot: Allows to record and display the data of
to appear. The Main Menu offers 4 different applica- malfunctions occurred. The displayed data not only
tions to select from. The desired menu can be executed includes the one corresponding to the moment
moving the highlight bar to it with the relevant function when a malfunction occurred, but also those that
key or selection keys and pressing the [ENTER] key. existed before and after the occurrence of the mal-
function. It also provides the function (Plot) to draw
graphs.
F1: Service Programming System (SPS)
Note:
Except industrial engine.
F2: View Capture Data

Allows to review data recorded under Snapshot of “F0:
Diagnostics”.
F3: Tool Options
Offers the function to make settings for the Tech2 main
unit, to display POST (Power On Self Test) results, and
to perform detailed tests (PCB, VCI).
• Tech2 Self Test: Performs troubleshooting on the
functions of the main unit.
WARNING:
Press [ENTER] While this function is under execution, do not con-
nect the unit to the machine!
• Set Clock: Sets the internal clock of the Tech2.

• Set Unit: Switches between the Metric system and
the English system.
• Set Contrast: Adjusts the brightness of the display.
F4: Down Load Up Load Help
The function to upload/download data (DTC, Snapshot,
etc.) acquired through the Tech2 to/from a PC, and the
Help function to render assistance in case the opera-
tion encounters a hitch.
Data display screen composition

The screen for data display is composed in the follow-
ing manner.
TSWG0086
F0: Diagnostics
Allows the user to check data, including Tech2-compat-
ible DTC (Diagnostics Trouble Codes), Data Display,
Snapshot, Miscellaneous Tests, etc., by selecting a
machine ID and System.
• DTC: Shows the contents and situation of DTC
stored in the controller of the system.
TITLE AREA
Shows the item currently selected.
MESSAGE AREA
Shows a supplementary explanation or instruction.
V DISPLAY AREA
V Displays data parameters and values (9 lines x 23
RPM characters)
RPM
V FULL TEXT AREA
V Shows details of the parameter under the highlight bar.
%
MPa SOFT KEY AREA
The softkeys below the function item display boxes are
valid.
TSWG0087
Name
1. TITLE AREA
2. MESSAGE AREA
3. DISPLAY AREA
4. highlight bar
5. FULL TEXT AREA
6. SOFT KEY AREA
List of functions of Tech2
TSWG0161
Diagnostic procedure
1. When the Tech2 is switched on, the software ver-
sion and the model year applicable to the software
will also be shown. Confirm the display and press
[ENTER].
TSWG0089
4. Select the Vehicle Type on the “Vehicle Identifica-

tion” screen and press the [ENTER] key.
TSWG0110
2. Press the function key [F0] or bring the cursor to

[F0: Diagnostics] on the “Main Menu” screen by
operating the selection keys (▲▼). And then,
press the [ENTER] key.
TSWG0090
5. Press the function key [F0] or bring the cursor to

[F0: Engine] by operating the selection keys (▲▼).
And then, press the [ENTER] key.
TSWG0088
3. Select the Model Year corresponding to the

desired diagnostic action on the “Vehicle Identifica-
tion” screen and press the [ENTER] key.
Note:
Select the model year of the relevant machine by
checking VIN of each machine.
TSWG0091 TSWG0093
6. Select Powertrain (Eng. name) on the “Vehicle 8. The following illustration shows the state in which
Identification” screen and press the [ENTER] key. the Tech2 is waiting for communication with the
machine controller. If the softkey “Next” is pressed
with the ignition key in “OFF”, this display will stay
forever. (State of communication disabled) How-
ever, turning the ignition key “ON” to “START” in
this condition will place the unit in the waiting state
for communication.
TSWG0092
7. The items chosen in steps 3 to 6 are shown in the

Message Area display section. If the identification
of the machine is OK, turn the ignition key “ON” to
“START” and press “Next” by following instructions
given on the screen.
TSWG0122
Note: 9. Once the communication is established, the unit
If you make any mistake, pressing the [EXIT] key will will show the part No. and DDI (Diagnostic Data
return you to the “Main Menu”. Identification) (which varies from a system to
another). Press the softkey “Confirm” and go on to
the application. If any mistake was made in the
selection of the vehicle type, despite that the com-
munication is enabled, a message to that effect will
appear flashing. If that is the case, check the vehi-
cle type again and redo the operation from step 1.
Depending on a machine, DTC is not clearing by
Tech2. (The memory clear harness on the machine
side needs to be connected to ground.)
DTC application menu display screen

[Example] Industrial Engine
F0: DTC Display
If no DTC stored
d
TSWG0094
Pressing [EXIT] key in the steps 3 to 9 will return

you to the “Main Menu” screen.
DTC check
1. Select “F0: Diagnostic Trouble Codes” on the
“Engine” screen.
TSWG0123
If DTC stored
TSWG0095
F0: Diagnostic Trouble Codes

This function allows the user to analyze the infor- TSWG0096
mation on the Trouble Code related to the system
currently under test. Data Display
2. Choosing “F0: Diagnostic Trouble Codes”, the fol- 1. Select “F1: Data Display” on the “Engine” screen.
lowing menu is displayed. F1: Data Display
F0: DTC Display Displays the information concerning various parts
F1: DTC Clear of the engine and transmission as data on the
F0: DTC Display screen of the Tech2.
Loads and displays the DTC information stored in the
machine controller in a priority order.
F1: DTC Clear
Softkey functions
A maximum of 5 data parameters can be fixed on the
“Data Display” screen. The 5 fixed parameters will be
retained at the upper part of the screen, even when the
display is scrolled up or down. To fix parameters, bring
the highlight bar to the desired parameter on the
screen, which appears as you select the softkey
“Select Items”, and press the [ENTER]. The selected
item can be identified by the asterisk (*) which will be
placed atop the parameter. Move the highlight bar with
the selection keys (▲▼), and once you have chosen all
the parameters you want fixed, press the softkey
“Accept”. “Data Display” screen is displayed again. To
modify the fixed parameter list, choose “Select Items”,
move the highlight bar to the parameter you want
changed, and press the [ENTER] key. The parameter
will be cleared. Choosing “Clear All” will clear all the
TSWG0097
fixed parameters.
2. F1: Choosing “Data Display”, the engine data is
If you select the softkey “DTC” while the “Data Display”
displayed.
function remains active, DTC will be displayed on the
“Data Display” screen.
Snapshot can be used while the “Data Display” function
remains active. For this, choose “Quick Snapshot.”
Choosing the softkey “More” allows to use additional
V functions.
V For “Quick Snapshot,” refer to 1E-38, “Snapshot,
RPM Tech2, How to Use Trouble Diagnosis-Related Tool”.
RPM
V
V
%
MPa
TSWG0098
V V
V V
RPM RPM
RPM RPM
V V
V V
% %
MPa MPa
TSWG0099
Snapshot About trigger type:
1. Select “F2: Snapshot” on the “Engine” screen. Choosing the Trigger Type Menu allows to check the
cause that triggered [Snapshot]. [Snapshot] is exe-
cuted when there is one of the three causes of occur-
rence.
F0: Manual Trigger:
Pressing the softkey “Trigger” saves data.
F1: Any Code:
Data is saved in case any trouble code is issued.
F2: Single Code:
Data is saved in case the specified trouble code is
issued.
About trigger point:

Trigger Point corresponds to the point in time where
triggering is originated by a code issued or by Manual
Trigger activated. This information is useful to know the
time point of Snap Point and to investigate changes in
the data parameter. Trigger Point can be set up at
“Beginning”, “Center”, or “End.”
TSWG0100
F4: Beginning
2. Choosing “F2: Snapshot”, the following menu is Starts saving data from Trigger Point, and keeps on
displayed. saving it, until the Snapshot recording area is filled up.
F0: Manual Trigger This selection is effective when the trouble that consti-
F1: Any Code tutes the cause is foreseeable.
F2: Single Code F5: Center
F4: Beginning This function is commonly utilized, since it saves not
F5: Center only the data after Trigger Point, but also those prior to
F6: End that. This selection allows to compare data that existed
Snapshot before the occurrence of a trouble, those present at the
Snapshot is intended to save information received by time of occurrence of the trouble, and those after the
the machine controller during its execution. It provides trouble, among themselves.
an effective means to analyze data generated when the F6: End
machine encounters a trouble. Use of this function Saves only the data prior to Trigger Point. This selec-
enables the user to focus on the situation in which the tion is useful when it is desired to terminate Snapshot
trouble took place, without having to view all the data after the occurrence of a trouble.
for suspected malfunctions. The Tech2 is capable of
holding two different Snapshot data. This ability of stor- Snapshot data replay
ing two different Snapshot data allows to compare 1. Press the softkey “Review Data” on the “Snapshot
Good and Bad machine states with each other. Since Options” screen.
these data are saved on a first-in, first-out basis, the
first Snapshot data (of older date/time) stored on the
PCMCIA card will be lost as it is overwritten when a
third data comes in. Therefore, be sure to set the inter-
nal clock of the Tech2 precisely before starting the
Tech2. If a given data must not be erased, highlight
that data and choose the softkey “Write Protect”. This
prevents the data from being overwritten. Pressing the
softkey “Clear” cancels the Protect.
Snapshot is available in the following 2 types:

• Snapshot: To be chosen in the Snapshot Menu.
• Quick Snapshot: To be chosen through the softkey
on the “Data Display” screen.
The Snapshot Data will not be lost even when the
Tech2 is switched off, because the data is saved on the
PCMCIA card.
TSWG0101
2. Move the highlight bar to the data you want 3. The selected parameter can be identified by the
replayed, and press the [ENTER] key. The data asterisk that appears at its top. No more than 3
will be replayed. parameters can be displayed.
TSWG0102 TSWG0104
4. Choosing the softkey “Accept” changes the display

Note: screen and shows a graph after a while.
Flashing “Trigger” means that data is being recorded.
Pressing the [EXIT] key in this condition will abort the
recording. The recording will also be cancelled when
the memory capacity is filled up. In either case, the
data is saved in memory.
Plot
Snapshot can also be replayed in “View Captured
Data.”
Plot setup procedure
1. Pressing the softkey “Plot” switches the “Data Dis-
play” screen.
RPM
MPa
TSWG0105
V Plot cancel
V
To close the graph display screen, press the [ENTER]
RPM
key and you will be returned to the “Data Display”
V
V screen.
%
TSWG0103
2. Bring the highlight bar to the parameter you want

plotted in a graph, as with “Select Items”, and
press the [ENTER] key.
Explanation of Plot data displayed • Move →: Allows to view changes of data following
the display screen.
• Trigger Frame: Displays a trigger point.
E
• More: Switches the displayed softkeys.
Choose the “More” on the plot display screen.
A
• Zoom In: Shows the abscissa by enlarging it (each
press doubles the display).
• Zoom Out: Shows the abscissa by reducing it
B (each press halves the display).
• Over View: Shows the entire frame.
Choose the “More” on the plot display screen.
• Time / Frame conversion: Switches the value in
D
abscissa.
Select frame
C
TSWG0106 1. Press softkey “Select Frame.”
Name
A. Maximum values of selected parameters
B. Minimum values of selected parameters
C. Values of selected parameters at Center Point
(E) in frame RPM
D. Number of frames/time MPa
E. Center point of graph indication
V
V
RPM
V
V
%
1
TSWG0103
2. Pressing the softkey “Select Frame” causes the

following screen.
TSWG0124
1. Denotes recognition of DTC.

A vertical line appears in abscissa, if there is a
Trouble Code issued in the Snapshot Data loaded.
When plotting a graph, it is advisable to check for
DTC through “Over View”.
2. DTC-recognized frame 236 (Actually issued in
Frame 235.)
Softkey functions
Choose the “More” on the snapshot graph display
screen.
• Move ←: Allows to view changes of data preceding TSWG0125
the display screen.
• First Frame: First frame No. and data acquisi- 2. Start the engine and run it at idle.
tion time from Trigger Point (calculated back- 3. Select the Common Rail System.
ward).
• Last Frame: Last frame No. and data acquisi-
tion time from Trigger Point (integrated).
• Go To Frame: Entering a frame No. allows to
view its data.
• +/-: Only the “-” sign is displayed.
3. “1” entered via keys in the “Go To Frame” area.
V
V
RPM
RPM
V
V TSWG0128
% 4. Select the Rail Pressure Test.

MPa
TSWG0107
Frame No. 1 and recording time displayed, and

data values in Display Area represent those of
Frame 1.
Actuator test
TSWG0130
TSWG0127
Common rail pressure control test

This test is performed to check the operation of RPCV.
The Tech2 must be used in this test.
Test procedure
TSWG0146
1. Connect the Tech2 to the machine DLC.
5. Send the instruction to RPCV and check the data
list.
V
V
RPM RPM
MPa RPM
V
V
%
TSWG0139
6. If the engine speed varies when the injector stops,

TSWG0147 electrical circuit of that injector is judged as normal.
6. If variation of data list is proper value, RPCV is If the engine speed does not vary when the injector
judged as normal. stops, electrical circuit of that injector or injector
body is judged as faulty.
Injector balance test
This test is performed to confirm that proper electric Injector control test
signal is sent to injector while the engine is running. This test is performed to confirm that proper electric
signal is sent to each injector. The Tech2 must be used
Note: in this test.
At test, the engine is controlled to low idle speed, in Test procedure
order to clarify the variation of engine speed. 1. Connect the Tech2 to the machine DLC.
Test procedure 2. Turn the key switch to ON (engine is standstill).
1. Connect the Tech2 to the machine DLC. 3. Select the Common Rail System.
2. Start the engine and run it at idle. 4. Select Compulsory Drive of Injector.
3. Select the Common Rail System.
4. Select Injection Stop for Each Injector.
TSWG0131
5. Send instruction to each injector (set to ON by soft-

key on Tech2 screen), and check the operation
TSWG0138
sound of injector.
5. Send instruction to each injector (set to OFF by
softkey on Tech2 screen) to stop the injector, and
check the variation of engine speed.
V
V
RPM
RPM
V
V
%
TSWG0132 TSWG0133
6. If the operation sound is heard, electrical circuit of 5. Send the instruction to glow plug relay and check
that injector is judged as normal. whether the lamp on the machine operates.
If the operation sound is not heard, electrical circuit
of that injector or injector body is judged as faulty.
Note:
After injector control test, the key switch must be turned
to OFF once to restart.
Glow time relay test

This test is performed to check the operation of QOS
lamp.
Test procedure
3. Select the Device Control.
TSWG0134
6. If the lamp operates properly, it is judged as nor-

mal.
EGR regulating valve test

This test is performed to check the operation of EGR
valve.
Test procedure
2. Start the engine and run it at idle.
3. Select the Device Control.
4. Select the EGR Control.
TSWG0137
4. Select the Glow Plug Relay.

TSWG0140 TSWG0110
5. Send the instruction to EGR valve and check the 2. Press [ENTER].
data list.
%
%
%
TSWG0108
TSWG0135 3. Choose “F2: View Capture Data” and press the

6. If variation of data list is proper value, EGR valve is [ENTER] key. “View Captured Data” appears.
judged as normal. 4. Choose “Snapshot Data” with selection keys (▲▼)
and press the [ENTER] key.
View captured data.
The Snapshot data acquired through the application
menu “F2: Snapshot” under the “Main Menu, F0: Diag-
nostics” can be replayed.
Since the data is saved on the PCMCIA card, it can be
viewed after disconnecting the Tech2 (DLC) from the
machine. Two data items can be saved there. The
internal clock of the Tech2 needs to be set precisely,
since the data are identified with dates and times.
Sample use of snapshot data replay

1. Turn on the power.
Softkey functions
1. Choose the softkey “More” on the Snapshot
Replay screen
• Select Items: Chosen to fix and display a
parameter (up to 5 parameters).
• Plot: Draws a graph (Up to 3 parameter items).
• Select Frame: Allows to specify a frame No.
and to move a parameter to the specified
frame.
2. Choose “More” out of the 4 softkeys on the display
screen.
• Auto Reverse: Allows to view changes of data
of each frame.
• Stop: Stops a frame in motion.
• Auto Forward: Allows to view changes of data
TSWG0109
of each frame.
5. Press the softkey “Continue” on the display
screen.
screen.
• First Frame: Allows to view the top data frame.
• Trigger Frame: Allows to view a triggered
frame.
• Last Frame: Allows to view the last data frame.
screen.
• Units: Changes the unit (speed/temperature).
• Previous Frame: Allows to view changes of
data by reversing it, frame No. by frame No.
• Next Frame: Allows to view changes of data by
feeding it forward, frame No. by frame No.
TSWG0126
screen.
6. Snapshot Replay Screen appears.
• DTC: Shows the frames in which a Trouble
Code was issued, in the range from the top
frame to the displayed frame.
• Previous DTC-Chg: Shows the frames in which
a Trouble Code was issued, in the range before
the displayed frame.
V • Next DTC-Chg: Shows the frames in which a
V Trouble Code was issued, in the range after the
RPM
displayed frame.
RPM
V • More: Switches the displayed softkeys.
V 6. Choose “More” out of the 4 softkeys on the display
% screen.
MPa The Snapshot Replay screen is restored.
Difference in operation of Snapshot Data Replay:

The operations of Snapshot Data Replay under “F2:
View Captured Data” are somewhat different from
TSWG0107 those of Replay (softkey function “Review Data”) under
“F2: Snapshot”. Be careful not to confuse them.
Tool options Note:
Each press on the [ENTER] key will increment the
Tool Options is the function to conduct a detailed test,
numeric value one by one, but it will not exceed the
in case communication cannot be established with the
preset maximum value.
machine at the time of setup of the Tech2 or at the time
of Power On Self Test (POST).
4. After all the values have been entered, press the
softkey “Set Clock” and the changes will be saved.
Tool option menu
F0: Tech2 Self Test
Allows to conduct a test that assists with the diagnos-
tics of the Tech2 itself. Normally the Self Test function
need not be executed, since the Tech2 conducts the
Power On Self Test (POST) every time it is switched
on. If the POST demonstrates any trouble, the results
of the POST can be checked choosing the Self Test
menu.
F1: Set Clock
Resets the date and time of the Tech2. Before exiting
this menu, press the softkey “Set Clock” to save the
settings.
F2: Set Unit
Switches the unit between the English and the Metric
system.
F3: Set Contrast
Changes the screen contrast (lighter or darker). The
change will be saved even after the Tech2 is switched TSWG0144
off.
Set units
Tech2 self test menu Operation procedure:
F0: Automated Main PCB and VCI 1. Choose the “F2: Tool Options” and press
Automatically executes function tests on the Main PCB [ENTER].
and VCI modules. 2. Choose the “F2: Set Unit” and press [ENTER].
F1: Automated Main PCB 3. Display the “Set Unit” screen, and move the cursor
Automatically executes function tests on the Main PCB to the item you want changed by operating the
module. selection keys (▲▼), and press [ENTER] key.
F2: Automated VCI
Automatically executes function tests on the VCI mod- 4. When the setup is complete, press the [EXIT] key
ule. to save the current setting.
F3: Selectable Main PCB
Note:
Allows to check detailed information on the PCB mod-
It will take effect next time the Tech2 is switched on.
ule test items.
F4: Selectable VCI
Allows to check detailed information on the VCI module
test items.
F5: Power On Self Test Results
Displays POST test results again.
Set clock
Operation procedure:
1. Choose the “F2: Tool Options” and press
[ENTER].
2. Choose the “F1: Set Clock” and press [ENTER].
3. Display the “Set Real-Time Clock” screen. Move
the cursor to the item you want changed by operat-
ing the selection keys (▲▼), and press the
[ENTER] key.
Rewriting of Q adjust correction data by
Tech2
“Q adjust, Injector code label” is attached to the cylin-
der head cover. It is used for rewriting and registering
the ID.
1 2 3 4
TSWG0145
*Metric
Temperature: °C Speed: km/h
*English
Temperature: °F Speed: MPH
TSHK0098
Name
1. Engine number
2. Typical engine model
3. Q adjust information
4. Injector information
There is the injector code on the top of injector as well.

When replacing the injector, register its code.
Refer to the following instruction for how to setup the Q
adjust data.
Step 1
• Press [ENTER].
TSWG0110
Step 2
• Choose the menu F0: Diagnostics with ▲, ▼ (up/
down) keys or F0 (function) key, and press
[ENTER].
TSWG0090
Step 5
• Choose F0: Engine in Menu with ▲, ▼ (up/down)
TSWG0088 keys or F0 (function), and press [ENTER].
Step 3
• Choose the menu (5) 2005 with ▲, ▼ (up/down)
keys, and press the [ENTER] key.
* Applicable for 2000MY or later.
TSWG0091
Step 6
• Choose 6HK1-TC (C/Rail_TIER3) with ▲, ▼ (up/
down) keys, and press [ENTER].
TSWG0089
Step 4
• Choose the menu (Off-Road) Industrial Engine
with ▲, ▼ (up/down) keys, and press the [ENTER]
key.
Step 7-1
TSWG0092
TSWG0122
Step 7
• Press the softkey “Confirm”. Step 8
• The ignition is ON at this time. • Press the softkey “Confirm”.
• This displays the ECU ID information.
TSWG0093
TSWG0094
Step 9
• Choose the menu F4: Programming with ▲, ▼ (up/
[ENTER].
TSHK0050 TSHK0052
Step 10 Step 12
• Choose the menu F0: Q adjust with ▲, ▼ (up/ • Password input screen
down) keys or F0 (function) key, and press • This procedure will end automatically if the regis-
[ENTER]. tration is not completed within 120 seconds.
The message “Time Over” appears.
TSHK0051
TSHK0053
Step 11
• Choose the menu F2: Service mode with ▲, ▼ Step 12-1
(up/down) keys or F2 (function) key, and press • After entering the password, press the [ENTER]
[ENTER]. key.
F0: Uploads the three-point Q adjust data stored in the • The password for 4/6HK1 is “SLNPTL4”.
ECM to the Tech2. • The password for 6WG1 is “SLNPTL6”.
* Registers the data when replacing ECM.
• Entering wrong password will return to the previ-
F1: Writes the three-point Q adjust data temporarily
ous menu.
stored in the Tech2 to the ECM.
* Registers to the ECM after replacing ECM.
F2: Any data can be written. However, password and
ID are required.
Note:
The ID code you have entered will appear on the
screen, suffixed with “0”.
The clock of Tech2 must be correctly set.
• After entering, press [ENTER] key.
TSHK0054
Step 12-2
• If the password you have entered is correct, press
the softkey [Okay].
• Enter the password within 120 seconds. Failure to TSHK0057
enter the password within 120 seconds will return

to Step 11. Step 14
• When the ID code matches, the following screen
will appear.
Press the softkey “Next”.
• This step can be performed only when the engine
speed is 0 rpm.
TSHK0055
Step 13
• After completing the password registration, pro-
ceed to ID registration.
TSHK0058
Step 13-1
Step 15
The numbers will appear on the screen. Obtain the ID
code from Hitachi Construction Machinery service • Displays the three-point Q adjust data in the ECM.
center by using this number (6855 in this case). 1. To modify the Q adjust data, press the softkey
Enter the obtained ID code (2495 in this case). At this “Change”.
time, the suffix “0” will be added to the end of it on the
Tech2 screen. Press the [ENTER] key.
TSHK0059 TSHK0099
Step 15-1 Step 15-2

• If the Q adjust data you have entered is correct, • If the Q adjust data you have entered is correct,
press [ENTER] key. press the softkey “Program”.
1. The entry conditions are as follows.
Conditions:
C/Rail system entry setting is “1 − 15”.
TIS system entry setting is “1 − 8”.
Note:
Q adjust information in the label attached to the cylin-
der head cover is given in hexadecimal number. Enter
it into Tech2 in decimal number as below.
Label information Enter into Tech2

1 1
2 2
3 3
4 4
5 5 TSHK0100
6 6
Step 15-3
7 7
• If the Q adjust data you have entered is off the set
8 8
value, the message shown as Step 15-4 appears.
9 9
A 10
B 11
C 12
D 13
E 14
F 15
TSHK0101 TSHK0103
Step 15-4 Step 16

• To go to Step15-5, modify the Q adjust data within • When the writing of data completes, the following
the set value and press the softkey “Program”. screen will appear.
This indicates that the result of comparison of
entered data with that written in the EEPROM of
the ECM is in good condition.
TSHK0102
Step 15-5
TSHK0104
• If the entered values meet the conditions in Step
15-1 and 15-3, the status display of data registra-
tion (writing) from the Tech2 to ECM as shown Step 16-1
below will appear. • If the entered Q adjust data in Step 15-1 does not
correspond to that written in the EEPROM of the
ECM, the following message will appear.
Pressing the softkey [End] returns you to Step 11.
Injector ID code (No. 1 cylinder - No. 6
cylinder) registration setting using Tech2
Preparation
If you plan to reflash the ECM part number at the QR
code registration setting, reflash first.
If you reflash after the registration, the QR code cannot
be correctly registered in ECM.
“Q adjust, Injector code label” is attached to the cylin-
der head cover. It is used for rewriting and registering
the ID.
1 2 3 4
TSHK0105
TSHK0098
Name
1. Engine number
2. Typical engine model
3. Q adjust information
4. Injector information
There is the injector code on the top of injector as well.

When replacing the injector, register its code.
Note:
Do not enter the six figures “0”, indicated with
strikethrough in the illustration, of ID code on the injec-
tor ID plate. Also, do not enter the letters at the end
with double strikethrough.
TSWG0088
Name
1. Injector ID plate Step 3
2. Injector ID code • Choose the menu (5) 2005 with ▲, ▼ (up/down)
3. Injector keys, and press the [ENTER] key.
Refer to the following instruction for how to register

Injector ID code.
Step 1
• Press [ENTER].
TSWG0089
Step 4
key.
TSWG0110
Step 2
[ENTER].
TSWG0090 TSWG0092
Step 5 Step 7
• Choose F0: Engine in Menu with ▲, ▼ (up/down) • Press the softkey “Confirm”.
keys or F0 (function), and press [ENTER]. • The ignition is ON at this time.
TSWG0091
TSWG0093
Step 6
Step 7-1
TSHK0050
TSWG0122
Step 10
Step 8 • Choose the menu F1: Injector ID code with ▲, ▼
• Press the softkey [Confirm]. (up/down) keys or F1 (function) key, and press
[ENTER].
TSHK0108
TSWG0094
Step 11
Step 9
• Choose the menu F1: ID code registration with ▲,
• Choose the menu F4: Programming with ▲, ▼ (up/ ▼ (up/down) keys or F1 (function) key, and press
down) keys or F4 (function) key, and press [ENTER].
[ENTER].
F0: Displays the Injector ID codes (hereinafter called ID
code) of Cyl.1-Cyl.6.
Allows you to confirm the ID code after registration.
F2: Uploads (transfers) the ID code (No. 1 cylinder −
No. 6 cylinder) registered in the ECM to Tech2 to
store in its memory.
F3: Allows you to download (batch registration) the
uploaded ID codes from Tech2 to the ECM.
TSHK0067 TSHK0069
Step 12 Step 12-2

• Press the softkey [Next].
• As an example, the vehicle will be checked
whether it is in the condition (engine stopped) that
the ECM requests during ID registration.
TSHK0070
Step 12-3
• You need to enter the ID on the following display.
TSHK0068 ID code is number of year. The following condi-
tions must be met.
Step 12-1 Conditions:
• The following display appears while checking if the 1. The time setting of Tech2 matches with the cal-
engine speed is 0 rpm. endar.
When the engine speed is 0 rpm, it will take you to 2. Press the function keys (F0 —F9) to enter.
Step 13.
TSHK0071 TSHK0073
Step 13 Step 15
• Choose the cylinder (No. 1 cylinder − No. 6 cylin- ID code registration (data entry)
der) you want to register the ID code with ▲, ▼ 1. The cursor is positioned at M (model code) in the
(up/down) keys, and press the [ENTER] key. default setting.
• As an example, this describes about No. 1 cylin- MCD0 D1D2
der. 2. At this point, enter the model code (MC) and ID
code (D0) in this order.
• Entering with the function keys (F0 − F9) will
automatically move the cursor to the right. How-
ever, if you enter with ▲, ▼ (up/down) keys,
you need to move the cursor with the arrow
(left/right) keys.
3. Data must be entered within $00 − $FF.
• You can enter 0 through 9 with the function
keys (F0 − F9), or 0 through Z with ▲, ▼ (up/
down) keys.
4. For VC17 (China), BCC code needs to be entered.
NK3 request
• Tech2 calculates the entered data and displays
the following message.
When entered ID code (QR) is off the set value:
Writing unable
TSHK0072
When entered BCC code is off the set value:
Writing unable
Step 14 When the ID code (QR) does not correspond to
BCC code: Writing unable
• To register the ID code, press the softkey
[Change].
• The ID code for Cylinder1 (No. 1 cylinder) selected
at Step 13 is shown here.
TSHK0074 TSHK0076
Step 15-1 Step 15-3

1. The model code (MC) for VC25 is $5A, the Tech2 If you have entered incorrectly (D7:$EG), do the follow-
specifies to register (write) $5A automatically. ing.
However you may also enter. 1. After pressing [ENTER] key as with Step 15-1,
Tech2 calculates the BCC code (BC) and registers press the softkey [Program]. This cause the error
automatically. message “Invalid data − Try again!” to appear.
Therefore, you do not need to enter.
2. Set the data entry limit judgment.
2. After entering the ID code input data byte (MC-D9), Judgment condition: Data (1 byte) meets the fol-
press [ENTER] key. lowing condition.
MSB:$F ≥ Data ≤ LSB:$F
• The following error message will be displayed
until the value that meets the condition is
entered.
TSHK0075
Step 15-2
• If the ID code you have entered is correct, press
the softkey [Program]. TSHK0077
If you want to quit the program (registration), press
the softkey [Abort] or press [EXIT] key. Step 16
• Quitting the registration or pressing [EXIT] key • If the entered values meet the conditions in Step
returns you to Step 11. 15-1 and 15-3, the status display of data registra-
tion (writing) from the Tech2 to ECM as shown
below will appear.
TSHK0078 TSHK0080
Step 17 Step 18
• When the ID code entered in Steps 15-1 and 15-3 • Pressing [EXIT] key returns you to Step 11.
corresponds to that registered in the ECM, the fol-
lowing message will appear. Also, if you want to
register ID again, press the softkey [Yes]. This
returns you to Step 13, and allows you make regis-
tration as before. Pressing the softkey [No] will
take you to Step 18.
This completes the ID code registration.
TSHK0081
TSHK0079
Step 17-1
• When the ID code entered in Steps 15-1 and 15-3
does not correspond to that registered in the ECM,
the following message will appear.
Pressing the softkey [End] returns you to Step 11.
ID code upload (Tech2)
Step 1
• Press [ENTER].
TSWG0089
Step 4
TSWG0110
key.
Step 2
[ENTER].
TSWG0090
Step 5
TSWG0088
keys or F0 (function), and press [ENTER].
Step 3
TSWG0091 TSWG0093
Step 6 Step 7-1

TSWG0122
TSWG0092 Step 8
• Press the softkey [Confirm].
Step 7
• Press the softkey “Confirm”.
• The ignition is ON at this time.
TSWG0094 TSHK0108
Step 9 Step 11
• Choose the menu F4: Programming with ▲, ▼ (up/ • Choose the menu F2: ID code upload (Tech2) with
down) keys or F4 (function) key, and press ▲, ▼ (up/down) keys or F2 (function) key, and
[ENTER]. then press the [ENTER] key.
TSHK0050 TSHK0060
Step 10
• Choose the menu F1: Injector ID code with ▲, ▼
(up/down) keys or F1 (function) key, and press
[ENTER].
Step 11-1 Step 12-1
TSHK0061 TSHK0061
Step 12 Step 12-2

• Pressing the softkey [Yes] updates the ID codes of • When the ID code registered in the ECM corre-
No. 1 cylinder − No. 6 cylinder stored in the ECM, sponds to that uploaded to the Tech2, the following
to the Tech2. message will appear.
Pressing the softkey [No] returns you to Step 11 Upload is completed.
without uploading the data. Pressing the softkey [Confirm] returns you to Step
• Upload is the function to transfer the registered ID 11.
code from ECM to Tech2 to store the data in it.
TSHK0063
TSHK0062
Step 12-3
• When the ID code registered in the ECM does not
correspond to that uploaded to the Tech2, the fol-
lowing message will appear.
Pressing the softkey [Confirm] returns you to Step
11.
• In this case, the uploaded ID code will be erased.
Therefore, perform upload again. The message
shown in Step 12-4 will appear.
TSHK0064
Step 12-4
• Pressing the softkey [Confirm] returns you to Step
11.
TSHK0065
ID code download (ECM)
Step 1
• Press [ENTER].
TSWG0089
Step 4
TSWG0110
key.
Step 2
[ENTER].
TSWG0090
Step 5
TSWG0088
keys or F0 (function), and press [ENTER].
Step 3
TSWG0091 TSWG0093
Step 6 Step 7-1

TSWG0122
TSWG0092 Step 8
• Press the softkey [Confirm].
Step 7
• Press the softkey “Confirm”.
• The ignition is ON at this time.
TSWG0094 TSHK0108
Step 9 Step 11
• Choose the menu F4: Programming with ▲, ▼ (up/ • Choose the menu F3: ID code download (ECM)
down) keys or F4 (function) key, and press with ▲, ▼ (up/down) keys or F2 (function) key, and
[ENTER]. then press the [ENTER] key.
TSHK0050 TSHK0088
Step 10
• Choose the menu F1: Injector ID code with ▲, ▼
(up/down) keys or F1 (function) key, and press
[ENTER].
Step 11-1
TSHK0091
TSHK0089
Step 12-2
Step 12 • The following display appears when the engine
• Press the softkey “Confirm”. speed is not 0 rpm.
In this case, stop the engine as instructed in the
• As an example, the vehicle will be checked message, and try again from Step 1.
whether it is in the condition (engine stopped) that
the ECM requests during ID registration.
TSHK0092
TSHK0090
Step 13
Step 12-1 • Pressing the softkey [Yes] downloads (registers)
the uploaded ID codes (Cyl.1-Cyl.6) to the ECM.
• The following display appears while checking if the Pressing the softkey [No] returns you to Step 11.
engine speed is 0 rpm.
When the engine speed is 0 rpm, it will take you to • Download is the function to register (write) the
Step 13. stored (uploaded) ID codes (No. 1 cylinder − No. 6
cylinder) in the Tech2 to the ECM. ID is registered
from No. 1 cylinder to No. 6 cylinder in the order.
TSHK0093 TSHK0095
Step 13-1 Step 13-3

• Registration is started from No. 1 cylinder (INJ.#1) • When the downloaded ID code does not corre-
to No. 2 cylinder (INJ.#5) and the ECM in the spond to that registered (written) in the ECM, the
order. following message will appear.
The status for registration (writing) of data to ECM Pressing the softkey [Confirm] returns you to Step
will appear. 11.
The message in the screen changes in the order of
No. 1 cylinder (INJ.#1) and No. 2 cylinder (INJ.#5).
When it is abnormal, the registration repeats 3
times.
TSHK0096
TSHK0094
Step 13-2
• When the downloaded ID code corresponds to that
registered (written) in the ECM, the following mes-
sage will appear. Download (registration) is com-
pleted.
Pressing the softkey [Confirm] returns you to Step
11.
TIS2000
TIS 2000 installation procedure
(Time needed: 30 minutes)
System Requirements 1. PC Free hard disk space: 150MB or more

OS: Windows 95 or higher RS-232C connector
CD-ROM drive
2. Distribution CD-ROM
• Internet Explorer version 4.01 or later is required to use TIS 2000.

• Internet Explorer version 4.01 (English version) will be installed automatically if prior to version 4.01 is installed,
or it is not installed on your PC.
1. Turn on the power to start-up Windows.

2. Insert the distribution CD-ROM into the CD-ROM
drive of PC.
3. The following screen will appear in approx. 10 sec-
onds.
• If the screen does not appear, open the file of
“Autorun.Exe” in the CD-ROM.
4. When the “Welcome” screen appears, click the
“Next”.
6. Usually, leave the “Destination Directory” as it is,

and click the “Next”.
5. Select the language to be used, and click the

“Next”.
7. On the “Choose serial port for Techline.” screen,

select the serial port of the serial cable to connect
Tech2 to the PC.
Normally, select the “COM1” and click the “Next”.
8. On the “Set HARDWARE_KEY” screen, select the 10. On the “TIS 2000 installation mode”, select the
“LPT” and click the “Next”. “Standalone” and click the “Next”.
9. On the “Salesmake” screen, select either the 11. On the “TIS 2000 Update” screen, click the “OK”.
“Isuzu - General Export (General Export VIN)” or
“Isuzu US (US VIN)” and click the “Next”.
[Example (UBS 6VE1 engine)]
General VIN: JACUBS26GY7100001
US VIN: JACDJ58X3Y7100001
12. If the installation is completed, the “TIS 2000” icon a. Startup TIS 2000.
is displayed on the desktop. b. Choose the “Snapshot Upload/Display” on the
• An error message may appear when restarting initial screen of TIS 2000.
the PC at Step 12. c. Either select the “Upload from diagnostic tool”
In this case, install the following file in the CD- or click the appropriate icon on the tool bar.
ROM.
d. Select the “Tech2” and transmit the saved
~cosids¥Diag¥Mdac_type.ex_
snapshot data.
Copy this file on your hard disk, change the file
name into “mdac.exe”, and double-click e. Select the “Transmitted Snapshot”.
“mdac.exe”. f. When the snapshot data transmission is com-
After this work, install TIS 2000 again. pleted, the data parameter list will appear on
the screen.
How to display snapshot
Fig. 2: Data display (sample)

Fig. 1: “Application Selection” screen 3. Display snapshot data with the “Snapshot Upload”
function of TIS 2000.
This describes about how to transmit and display Snapshot data are stored in the PC hard disk or
Tech2 snapshot data using the “Snapshot Upload” floppy disk, and they can be displayed any time.
function of TIS 2000. Snapshot data can be displayed Stored snapshot can be displayed in the following
with the “Snapshot Upload” function of TIS 2000. The procedure.
trouble symptom can be checked by analyzing snap- a. Startup TIS 2000.
shot data with various methods. To display the snap- b. Choose the “Snapshot Upload/Display” on the
shot data, perform the following 3 steps; initial screen of TIS 2000.
1. Record the snapshot data in Tech2. c. Either select the “Open file” or click the relevant
2. Transmit the snapshot data to PC. icon on the tool bar.
After recording the snapshot data to Tech2, trans- d. Select the “Transmitted Snapshot”.
mit the data from Tech2 to PC in the following pro-
cedure. e. When the snapshot data opens, the data
parameter list will appear on the screen.
Icons to be displayed
The following icons are used for data display.
Transmits the snapshot from Tech to PC.

Uploads the snapshot data from the floppy disk or hard disk.
Saves the snapshot data on the floppy disk or hard disk.
Displays the data parameters in one frame.
Displays the data parameters in two frames.
Changes the unit.
Displays the data parameters in graph and list (up to 3 parameter items for graph display).
Selects/cancels the parameter.
Displays the data parameters in graph only (up to 6 parameter items).
Prints (data parameter print out).
Snapshot data replay

Snapshot data can be replayed using icons in the bottom of the screen.
1st record: Displays the first record of the snapshot.
Previous record: Displays the previous record of that currently displayed.

Regeneration in reverse direction: Replays in the reverse direction.
Trigger of record: Moves to the trigger position and displays the snapshot.
Regeneration in forward direction: Replays all the snapshot in the forward direction.
Next record: Displays the next record of that currently displayed.
Last record: Displays the last record of the snapshot.
End of regeneration: Clicking the snapshot ends the replay of record.
Graph display
Numeric value and graph (up to 3 for graph display):
1. Clicking the icon for graph display opens “Graph
Parameters.” window.
2. Click the 1st graph icon in the top of the window,
and select one parameter from the list in the bot-
tom of the window. Selected parameter is shown
next to the graph icon. Graph category can be
selected with the field located in the right hand of
the parameter.
3. Perform the same procedure for the 2nd and 3rd
graph icons.
4. After selecting all the parameters (up to 3 parame-
ters) you wish to view, click the [OK] button.
Fig. 4: “Graph Parameters.” window (sample)

5. Selected parameter is shown in graph form, in the
right hand of the data parameter on the screen.
3. Perform the same procedure for the 2nd to 6th
parameters with graph icons.
4. Clicking the [OK] button displays the graph.
5. In this case, parameters are available only in graph
form. All the parameters are shown in one frame.
Fig. 5: Graph display screen (sample)

6. Graph display can be moved with the navigation
icons.
7. If you wish to view the graph with different parame-
ter, drag the parameter in the list onto the display
screen. (Click the parameter and move the cursor Fig. 7: Graph display screen (sample)
with the mouse button pressed, and then release 6. Graph display screen can be moved with the navi-
the mouse button in the display screen. ) New gation icons.
parameter appears to replace the old one. To view
the graph in full screen, move the cursor to the top Selects/cancels the parameter.
of the screen, and click the screen where the cur- Use of parameter select/cancel function allows to
sor changes to magnifying glass icon. This will dis- select particular parameter from the list and to display it
play the graph in full screen. instantly. First click the parameter you want to view to
mark it, then click “Select/Cancel Parameters”.
Graph display in one frame (up to 6 for graph dis-
Selected parameter is shown in the upper area of [Lock
play)
line] on the top of the data list. Other parameters can
1. Click the “Six graph” icon. This opens “Graph be added in the same procedure. Use of parameter
Parameters.” window. [LOCK] allows the parameters to be displayed continu-
ously for data comparison. To eliminate a parameter
from the list, click the parameter you want to eliminate
to put mark on it, then click “Select/Cancel Parame-
ters”. When quitting the [Snapshot Display] application,
“Do you want to save this file?” dialog box appears
automatically. The file can be saved on the PC hard
disk or floppy disk.
Fig. 6: “Graph Parameters.” window

2. Click the graph icon, and select the parameter you
wish to view from the list. Change the graph cate-
gory as required.
Directory to save data
Normally data is saved in “C:¥Program
Files¥cosids¥DATA¥SNAPSHOT¥” folder. This direc-
tory is different if you changed installation directory
when installing the application. Two sample files
(“10000000SUR”, “10000001.SUR”) are already stored
when installing the application.
Fig. 8: Parameter selection
TIS 2000 navigation

TIS 2000 application can be operated using the following icons.
[TIS2000 end]: Quits all TIS 2000 applications to return to the Windows desktop screen.
[Select page]: Returns to the initial page of TIS 2000 without quitting applications currently used. The
applications currently used run in the background.
[Vehicle data]: Starts [Vehicle data display] function. This displays all the vehicle information.
[Executed applications end]: Quits the application currently used to return to the initial page of TIS 2000.
[Session]: Allows to register and display user information.
[Print]: Prints the screen.
[Help]: Launches the integrated help function of TIS 2000.

Software download
Fig. 2: Selection of diagnostic tool to be updated and update

mode
Fig. 1: “Application Selection” screen
• Check the selected location and click “Next”. An
Herein, it is described about how to update Tech2 soft- explanation appears as “Reading information of
ware using “Software Download.” function of TIS 2000. diagnostic tool”.
6. The “Software Update Confirmation” screen
Updating Tech2 (Software download) appears on the PC.
Update the Tech2 software to the latest version using Also, the stored contents of the current Tech2 and
“Software Download.” function of TIS 2000. stored data after transmitting diagnostic software
Tech2 software is updated on a regular basis to corre- appear on the screen. Click the [Continue] to go
spond to the change in vehicle specifications and diag- on.
nostic methods. Updated information includes new 7. “Transmitting Software” appears on the screen to
vehicle system, amendment of diagnostic method, tell the transmission status.
update from previous version, addition of new diagnos-
8. When the transmission is completed, “Transmis-
tic method, etc.
sion is completed” will appear on the screen. Click
There are two kinds of download mode; “Standard” and
the “Close” button to quit the application. The latest
“Custom”.
software has been transmitted to the diagnostic
Standard update (This mode is not used this time.
tool.
Select the “Custom”.)
Description: Standard mode can be used only when the Custom update
old version of software is installed and registered in the
database. Only “Custom” mode can be used in any Use custom update when installing the old version soft-
other cases. In “Standard” mode, the latest version will ware, software other than Isuzu software or software
be installed for the language and the model (manufac- with different language, or when the database cannot
turer) which are set in Tech2 at that time. identify the software version being installed. After
The procedure of Tech2 “Standard” update, using selecting “Custom” on the selection screen (See Fig.
“Software Download.” function, is as follows. 2), perform the following procedure.
1. Connect the Tech2 to the PC with RS232C cable. 1. The “Application Selection” appears on the screen.
The list of the software release No. appears on the
2. Connect the standard accessory power cable to left hand of the screen. Clicking [+] mark allows to
Tech2. view the list of available language of each release.
3. Startup TIS 2000 on the PC.
4. Choose “Software Download.” icon on the initial
screen of TIS 2000.
5. Check the selected location on the “Select Diag-
nostic Tool for Download” screen, and go to next.
3. Clicking the [Download] button starts updating.
4. “Transmitting Software” appears on the screen to
tell the transmission status.
5. When the transmission completes, “Transmission
is completed” will appear on the screen. Click the
“Close” button to quit the application. The selected
software has been transmitted to the diagnostic
tool.
Fig. 3: Selection of application for “Custom” mode

2. Either double-click the relevant software version
and language, or click the “Select” button to select.
The software you have chosen appears on the
right hand of the screen. To compare current soft-
ware with selected software of the diagnostic tool,
click the mark on the right hand of the screen.
TIS 2000 navigation

TIS 2000 application can be operated using the following icons.
[TIS2000 end]: Quits all TIS 2000 applications to return to the Windows desktop screen.
[Select page]: Returns to the initial page of TIS 2000 without quitting applications currently used. The
applications currently used run in the background.
[Vehicle data]: Starts [Vehicle data display] function. This displays all the vehicle information.
[Executed applications end]: Quits the application currently used to return to the initial page of TIS 2000.
[Session]: Allows to register and display user information.
[Print]: Prints the screen.

[Help]: Launches the integrated help function of TIS 2000.
Snapshot transmission method using e-mail

• Upload the snapshot data from Tech2 to hard disk
on PC.
• Open the file in the following procedure to down-
load data.
• Double-click “C: ¥Program Files”.
• Double-click the “cosids” folder.
• Double-click the “Data” folder.
• Double-click the “SNAPSHOT” folder to download.
• Make sure that the file extension is “.sur”, and
attach the file to e-mail.
How to Inspect Injector

How to use injector checker
Components of injector checker
TSWG0211
Name
1. Injector checker body 3. Test harness for 4-cylinders
2. Test harness for 6-cylinders
• To prevent wrong connection, the end of corrugate tube of connection harness for 6-cylinders is wrapped by
identification tape (red) for 4-5-6 cylinder side harness.
Each part of injector checker • Do not turn the selection switch excessively after it
is turned to stopper.
Start switch
This is used to stop the cylinder selected by the cylin-
der selection switch. Injection of selected cylinder stops
4
approx. 2.4 seconds.
Operation lamp
This comes on while injector is checked (approx. 2.4
seconds) after starting button is pressed.
3 5
Note:
Do not use any switches and operate the machine
2
while the lamp comes on. Otherwise, diagnosis result is
not correct.
Holder
1
Holders are used to hang or fix the body. They are
tightened on the body. To use the holders, loosen the
TSWG0212 screws to move.
Name
Note:
1. Main switch
2. Battery lamp • When using or storing holders, be sure to tighten
3. Operation lamp them to fix.
4. Cylinder selection switch • Be careful not to tighten screws excessively. This
5. Start button may damage the body.
Main switch
This is used to switch ON and OFF of injector checker
function.
Note:
Be sure to turn it to OFF before removing/installing har-
ness.
Battery lamp
This comes on when the battery (9V) in the body gets
low (7.2V or less).
If the battery lamp comes on, replace the battery as
soon as possible. (Refer to 1E-85, “Battery Replace-
ment, How to use injector checker, How to Inspect
Injector”.)
Note:
When using the main switch, it comes on momentarily TSWG0221
due to voltage change. If the battery lamp does not
come on when using the main switch, check the bat- Precautions on handling the body
tery. Replace it if it gets low (7.2V or less).
• The body is a precision equipment. Do not
Cylinder selection switch drop it or make a high impact on it.
This is used to switch a cylinder to be checked. Turn it • The body is drip-proof type. However, avoid
left fully before check, and then start to check clockwise using it in rainy day or operating with wet
(1 → 2 → 3 → 4 → 5 → 6). hands to prevent water from entering through
connector connection.
Note: • Power for the body must be supplied from
• One rotation of cylinder selection switch allow to internal battery, not from external one.
check twice for each cylinder. At the third time or • Prevent foreign matter from entering into the
later, turn the selection switch left back to the origi- body while replacing battery.
nal position and start to check.
• Do not use screws to tighten battery holder Note:
except original ones. This may cause body • Be careful not to let the metal parts of test harness
damage or battery damage and electric leak- and connector contact glow plug connector. Protect
age. it with cloth to prevent short during operation of key
• Do not disassemble the body in any circum- switch.
stances. Contact Hitachi Construction • Do not connect wrong connector. (Confirm the iden-
Machinery. if it is faulty. tification tape (red) before connecting.)
• DTC will be detected if disconnecting or connecting
the harness with the key switch to ON. Turn it to
Injector test OFF during work.
1. Check the DTC.
• If DTC unrelated to injector is detected, repair
or check to eliminate the faults before test.
3. Disconnect the injector connector from engine on
the machine. (4-cylinder: one, 6-cylinder: two)
4HK1
TSWG0215
* 4HK1 is shown in the illustration.
Note:
Be careful not to let the metal parts of connector con-
tact glow plug connector while connecting the harness.
TSWG0213
6HK1
#4,5,6
#1,2,3
TSWG0216
5. Connect the test harness to the body.

• Do not directly place the body on the engine.
TSWG0223
• Avoid high vibration and impact.
4. Connect the test harness to the engine side.
Battery Replacement
1. Remove the two screws on the side of the body.
TSWG0214
6. Start the engine.

7. If the machine has function to lower idle speed, TSWG0217
lower the speed to clarify the engine reaction. 2. Pull out the battery holder.
8. Set the selection switch to “1”, and check the No. 1
cylinder.
9. Press the start button and check the engine vibra-
tion level and change in exhaust noise.
• If it is difficult to recognize the change, touch
the engine directly to check change in the vibra-
tion.
Note:
Do not operate the body and the machine while the
operation lamp comes on.
10. Confirm that the lamp goes off and repeat check of
the remaining cylinders as steps 8 and 9.
11. Replace the injector in the cylinder of which engine
vibration level and exhaust noise did not change.
Note:
TSWG0218
For work procedure, refer to “Engine section” in the ser-
vice manual. 3. Remove the battery from the holder.
12. Turn the key switch to OFF, remove the test har-
ness, and restore the injector harness.
Note:
DTC will be detected if disconnecting or connecting the
harness with the key switch to ON. Turn it to OFF dur-
ing work.
13. Start the engine and return the idle speed at speci-
fied one.
14. Clear the DTC.
15. Refer to the machine’s manual for how to clear
DTCs.
16. Perform a test drive, and check that there are no
faults.
Method to identify using non-contact
infrared thermometer
There are three methods to identify injectors as follows.
Since the method varies depending on the necessary
tools you have, and/or the judgment difficulty of each
machine, refer to the section of Hitachi Construction
Machinery.
Method to identify
1. Method of judgment by an injector balance test
using a diagnostic tool with KW or CAN communi-
cation such as Tech2.
• For the procedure of a balance test, refer to 1E-
42, “Injector balance test, Tech2, How to Use
Trouble Diagnosis-Related Tool”.
2. Method of judgment by such an injector balance
TSWG0219
test that the injector power line is broken for a short
4. Disconnect the connector from battery, and time using an injector checker without communica-
replace the battery. tion with the ECM.
• Refer to 1E-82, “How to use injector checker,
How to Inspect Injector”.
3. Method of judgment by measuring and comparing
the rising trend of the exhaust temperature using a
non-contact infrared thermometer.
Depending on machine types, proficiency may be
required to judge only using an injector checker when a
diagnostic tool is not available. If it is difficult to judge,
we recommend the method of measuring and compar-
ing the rising trend of exhaust pipe temperature using a
non-contact infrared thermometer.
Method to measure
Use a non-contact infrared thermometer capable of
measuring 500°C (932°F), and continuously measure
at a rated point (for excavators, the points on two pump
relief) on the engine which you can stably measure.
TSWG0220 Measuring period should be 3 to 5 minutes after the
5. Restore in the reverse order. engine stabilized. Measure and compare the exhaust
pipe temperature of each cylinder, and judge as faulty
Note: cylinder if the temperature of certain cylinder is signifi-
cantly lower than others.
• Prevent foreign matter from entering in while remov-
ing the battery.
Comparing exhaust pipe temperature of
• Do not tighten the battery holder screws exces-
engine unit alone
sively.
Note:
• Do not replace the battery holder screws with other
than original ones. • Reference for test on engine unit. Test results will
show similar tendency when trouble occurs
• Be sure to use specified battery.
although variation may differ depending on
machine type and measuring conditions.
• Be careful not to continue the test condition for a
long time. Otherwise the test result may be incor-
rect due to heat conduction of the exhaust pipe.
Changes in the temperature in the normal condition Changes in the temperature when injection in one
of No. 2 to No. 5 cylinders stops
500
(932) 500
(932)
400
400 (752)
(752)
300
C ( F)
(572)
C ( F)
#2 - #5
300 200
#6
(572) (392)
100
(212)
200
(392) 0
TSHK0135 (32)
TSHK0137
In the normal condition, the temperature of the No. 6
cylinder keeps lower than others. When injection in one of No. 2 to No. 5 cylinders stops,
the temperature of the stopped cylinder keeps lower
Changes in the temperature when injection in 1st
than normal cylinders.
or No. 6 cylinder stops
Note:
500 Refer to the relevant section for the reference value of
(932)
Hitachi Construction Machinery.
400
(752) Injector balance test (Tech2)
Refer to 1E-42, “Injector balance test, Tech2, How to
300
(572) Use Trouble Diagnosis-Related Tool” for injector bal-
C ( F)
ance by Tech2.
200
(392)
100
(212) #1/#6
0
(32)
TSHK0136
When injection in No. 1 or No. 6 cylinder stops, there

are significant difference in the temperature between
No. 1 or No. 6 cylinder and other cylinders that perform
normal injection.
Flash Tool (EMPS)

Introduction
Only the person with approval of the machine man-
ufacturer or engine manufacturer can reflash ECM
using EMPS.
Cautions
For your safety, read the following cautions.
1. Always turn the POWER switch of EMPS selector
to OFF before connecting/disconnecting the
cables. Before turning on the POWER switch of
EMPS selector, make sure that the cables are con-
nected securely.
6. Avoid using and storing it in a place that it may

contact water or chemicals. When cleaning, use
cloth with mild detergent, not highly-volatile solvent
such as thinner, and wipe out using dry cloth.
2. Do not disassemble the EMPS selector.

3. ECM can be reflashed up to around 100 times.
(The number of times varies depending on the
conditions of use.)
4. If the POWER lamp does not come on when turn-
ing the POWER switch ON with the power source
connected, check the fuse.
5. Do not have an impact on it by dropping. It causes
internal faults even no damage on appearance. 7. Avoid using and storing it in dusty area. Store it to
avoid dust on the connector etc. when you don’t
use.
8. Avoid using and storing it in a place with rapid

changes of temperature. If bringing it from cold
outside into warm indoor suddenly, dew condensa-
tion may occur resulting in malfunction or trouble.
9. Avoid using and storing it in a place with extreme

high or low temperature. Especially in summer, do
not leave it in the machine exposed to direct sun-
light.
EMPS Component Parts
11
5 4 3 2 1
6 7 8 9 10
Name
1. Selector 7. ECM connector
2. ECM POWER switch 8. Fuse
3. DATA SELECT switch 9. POWER switch
4. READY lamp 10. ECM connection cable
5. POWER lamp 11. Battery cable
6. RS-232C connector
Caution:
Power supply: You can use an AC adapter, however, AC adapter is not provided in the component parts.
Prepare an AC adapter that meets the specification. Available DC plug model number is MP-121C (outer
diameter: 5.5 mm × inner diameter: 2.1 mm, DC 12 V – 0.5 A).
Note:
If your PC has no RS-232C port, you can use a USB to RS-232C converter (optional) to connect.
However, error may occur during reflashing with some converters.
The converter shown below was verified for operation.
Manufacturer Product name Model JAN code

Arvel USB Serial Cable SRC06-USB 4950190541981
ECM (hardware) compatibility
• ECM (hardware) that can be reflashed has no compatibility.
Use the ECM that corresponds to the engine type and voltage specification.
Voltage Specifications
Remarks
12 V specifications 24 V specifications
4HK1 4HK1
6HK1 6HK1
Eng Model 6WG1 6WG1
ECM (hardware) for 6WG1 and 6U is the same.
6U 6U
4J 4J
• Using EMPS can reflash the ECM of industrial common rail engine only.
• Using EMPS cannot reflash the ECM of industrial engine (RED – 4 type injection system) that meets Phase 2
Emission Standards.
System Requirements for EMPS Software (Recommended)
System Component Specifications

PC PC/AT compatible machine
CPU Pentium III 800 MHz or more
OS Windows 2000 SP4, Windows XP SP1, SP2 in Japanese or English version
Memory 256MB or more
HDD 20GB or more
Video card 1024 × 768 dots or more, 256-color or more

Serial interface One or more RS232C ports (USB conversion connector etc. is also available)
External drive CD-ROM drive

EMPS (software) Setup Procedure
1. Insert the “EMPS setup CD” into the CD-ROM
drive.
This automatically starts up the setup program,
and the following message appears.
Quit other application if it is running. Click the [OK]

button.
To cancel installation, click the [Cancel] button.
3. Configure operating environment.
Configure the work folder that system uses, the ini-
tial value of the COM port, and the initial value of
the data transmission rate, and click the [Com-
plete] button.
COM port and data transmission rate can be
changed later. If you are not sure about this set-
ting, do not change the value and click the [Com-
plete] button.
Read the license agreement. If you agree to the

terms, click [Agree to the terms of this agreement]
and click the [OK] button.
If you do not agree, click [Disagree to the terms of
this agreement] and click the [OK] button to end
the setup.
2. Enter the user name and password, and then click
the [Next] button.
4. After the user name and password are verified, the

following display appears.
Click the [Next] button.
5. In the following display, confirm the installation 7. Setup completion

destination and click the [Next] button. The setup is completed, and the following display
To change the installation destination, click the appears. Select [Yes, I want to restart my com-
[Browse] button and select the folder you want to puter now.], and then click the [Finish] button.
install.
Note:
You can also select [No. I want to restart my computer
later.], but unexpected error may occur if you reflash
with the EMPS before restart. Be sure to restart the
computer before starting the EMPS.
6. This starts the setup, and the following display

appears.
To cancel the setup halfway, click the [Cancel] but-
ton.
System version upgrade
If the system has been upgraded, the update program
will start automatically after the CD is inserted.
The following message will appear. Quit the EMPS if it
is running, and click the [OK] button.
Clicking the [Cancel] button cancels the update pro-
cess. Update must be performed before reflash with
EMPS.
EMPS Operation Procedure

1. Preparation
This section describes preparation for starting the EMPS program.
1.1 Preparation
1. Printed label with update parts number is necessary to proceed reflashing in all countries except the US. Pro-
ceed next steps to get updated parts number. Contact pt_service@notes.isuzu.co.jp in order to obtain the
updated parts number label. If engine is certified in the US, it is not necessary to replace the label. Proceed all
steps.
2. After reflashing, you need to write down the new Parts Number on a label and attach it on the ECM.
3. Check the serial number of the selector, and have your user ID and password ready.
4. Check the engine serial number.
5. To perform compulsory reflash, obtain the specific password from the machine manufacturer or the engine
manufacturer.
1.2 EMPS Selector Connection
Using power supply 4
6
DATA ECM
SELECT POWER
POWER READY READ ON
2 WRITE OFF
RS-232C ECM FUSE POWER
3 1
5 7
Using battery 5
6
DATA ECM
SELECT POWER
POWER READY READ ON
2 WRITE OFF
RS-232C ECM FUSE POWER
3 1
5 7
Name
1. Power SW 5. Battery cable
2. RS-232C cable 6. Selector
3. ECM harness 7. ECM
4. AC adapter cable (option)
Connection Procedure • Use the optionally available AC adapter when

1. Turn the POWER SW to OFF. drawing power with an AC adapter.
2. Connect the RS-232C cable. • Prepare the AC adapter that matches the rating
(12V/24V) of the ECM when drawing power with
3. Connect the ECM harness.
an AC adapter.
Note: • Do not use a battery at the same time when
Do not roll up the harness cord. drawing power from an AC adapter.
• Do not roll up the ECM harness. Data commu-
4. Connect the AC adapter or battery cable. nication error will result.
5. Insert the Data CD into the PC. • Make sure that the POWER switch of EMPS
selector is turned to OFF before connecting/
Removal Procedure disconnecting the ECM harness. Damage to
1. Turn the POWER SW to OFF. EMPS or ECM selector will result.
2. Remove the AC adapter or battery cable.
3. Remove the ECM harness.
4. Remove the RS-232C cable.
5. Eject the Data CD from the PC.
Caution:
• Do not use an AC adapter at the same time
when drawing power from a battery.
2. ECM Reflash
This section describes the process procedure for nor-
mal reflash.
2.1 Startup
Double-click the “EMPS” icon on your Windows desk-
top to display the initial startup screen.
Select the [ECM Reflash], and click the [Next] button to

advance to Connection Procedure.
Power Supply Connection
Clicking the [Next] button displays the message shown

below.
Clicking the [OK] button displays the Process Menu

screen.
Battery Connection Campaign Update (Campaign)
This is performed at the campaign designated by man-
ufacturer. After reflashing, send the campaign log file
created to the administrator.
Select [Normal Update], [Enforce Update] (compulsory

reflash), or [Campaign Update], and then click the
[Next] button.
One of the following operations is performed when
the [Next] button is clicked.
Selected Option Settings/Operation Performed
Normal Update Advances to “2.2.1 User Authentica-
tion Screen” – “For [Normal] or [Cam-
paign].”
Enforce Update Advances to “2.2.1 User Authentica-
tion Screen” – “For [Compulsory
Reflash].”
Campaign Update Advances to “2.2.1 User Authentica-
Connect the PC, selector, and ECM according to the
paign].”
procedure.
After connection, click the [Next] button to proceed to
the mode selection screen. Clicking the [Next] button displays the message shown
below.
Name
1. Normal Update Check the content, and click the [OK] button to
2. Enforce Update advance to next.
3. Campaign Update
[Normal Update] (normal reflash)

Compatible parts number with reflashed parts number
is searched automatically and updated.
[Enforce Update] (compulsory reflash)
An arbitrary parts number is designated and updated.
Select this when reflashing was failed, or when reflash-
ing the parts number with no compatibility.
Specific password is necessary.
2.2 User Authentication Screen
This screen is used for EMPS user authentication.
2.2.1 User Authentication Screen

For [Normal] or [Campaign]
After entering information in the [ID] and [PASSWORD]
fields, click the [Next] button to advance to “2.2.2 OEM
Manufacturer Selection Screen.”
To cancel user authentication at any point, click the
[Cancel] button.
For [Compulsory Reflash]

After entering information in the ID, PASSWORD, and
Enforce Update PASSWORD (Password for compul-
sory reflash) boxes, click [Next] to advanced to “2.2.2
OEM Manufacturer Selection Screen.”
[Cancel] button.
2.2.2 OEM Manufacturer Selection Screen

After selecting the OEM manufacturer, click the [OK] to
advance to “2.3 Connection Confirmation Screen.”
2.3 Connection Confirmation Screen One of the error messages will appear if an error is dis-
covered by the check that is performed when the [Next]
This screen shows the connection status of the com-
button is clicked. Refer to “7. Error Messages.”
puter, selector, ECM, and power supply/battery.
Power Supply Connection 2.3.1 PC Setting
Normally select COM1 if RS232-C is used for connec-
tion.
In the case of a PC that is not equipped with an RS232-
C port, connect using a commercially available USB
conversion cable. For details about port settings, refer
to the user documentation that comes with the USB
conversion cable.
To check standard COM port settings
1. On the Windows [Start] menu, select [Control
Panel].
2. On [Control Panel], open [System].
3. When system properties appear, select [Hard-
ware].
WindowsXP
Battery Connection
Windows2000
After selecting the COM port (Communication port) and

transmission bit rate (Bit/sec), click [Next] to advance to
“2.4 Switch Confirmation Screen 1.”
Selection Item Descriptions
Items Description
COM port Select the RS232C port to which the
selector is connected.
Transmission bit Select the data transmission bit rate.
rate
Cancel button Displays a confirmation message for
exiting the tool.
4. Select [Device Manager] to open it.
Next button Performs a check and then displays
5. On [Device Manager], select [Ports (COM & LPT)].
2.4 Switch Confirmation Screen 1
WindowsXP
After checking to make sure that the initial settings of
the switches are as shown on the screen, click the
[Next] button.
Windows2000
Turn on the power switch, and then click the [Next] but-
ton.
6. In the displayed items for communication ports,

confirm the COM port to which the EMPS is con-
nected.
This starts selector confirmation, and displays the mes- 2.5 Selection Menu
sage shown below.
After selecting the [Select ECM Location], click the
[Next] button.
If response from the selector is normal, advance to “2.5

Selection Menu.” Selection Item Descriptions
One of the following messages will appear if any abnor-
Items Settings/Operation Performed
mality is discovered. Click the [Return to User Authenti-
cation screen] button, and check the user ID. To Process Menu The process selected in “2.1 Startup”
continue the process as is, click the [Continue process] will appear.
button. Select ECM on the machine
Location off the machine
Back button Returns to “2.3 Connection Confirma-
tion Screen.”
Next button When [off the machine] is selected,
advances to “2.5.1 External Power
Confirmation Screen.”
When [on the machine] is selected,
advances to “2.5.2 Voltage Confirma-
tion Screen.”
2.5.1 External Power Confirmation Screen

This screen prompts for confirmation of an external
power supply.
If a communication error occurs, advance to the “6.

Recover Point” screen.
Clicking the [Yes] button after checking the connection Clicking the [Yes] button after checking the voltage of
of external power supply advances to “2.6 Selection power supply advances to “2.6 Selection Items Confir-
Items Confirmation Screen.” mation Screen.”
If an external power supply cannot be connected, click If power supply cannot be confirmed, click the [No] but-
the [No] button to return to “2.5 Selection Menu.” ton to return to “2.5 Selection Menu.”
Clicking the [Help] button will display the message Clicking the [Help] button will display the message
shown below. shown below.
2.5.2 Voltage Confirmation Screen

This screen prompts for confirmation of proper voltage.
2.6 Selection Items Confirmation Screen 2.7 Switch Confirmation Screen 2
This screen shows the details of the settings configured The switch confirmation screen is shown below.
up to this point.
If there is no problem with the displayed settings, click
the [Next] button to advance to “2.7 Switch Confirma-
tion Screen 2.”
To change the settings, click the [Back] to return to “2.5
Selection Menu.”
Configure the switch settings as shown below.
DATA SELECT switch: READ

ECM POWER switch: ON
After configuring the switch settings, click the [Next]

button.
This starts uploading Parts Number and displays the
message shown below.
Then, injector QR code is uploaded. (The following

screen will be displayed briefly.)
To return to “2.8 Current ECM Parts Number Confirma-
tion Screen,” click the [Back] button.

Current ECM Parts Number Confirmation Screen.”
One of the messages will appear if any abnormality is Selection Item Descriptions
discovered. Refer to “7. Error Messages.” Items Settings/Operation Performed
ENGINE MODEL Select the engine model that corre-
2.8 Current ECM Parts Number Confirmation sponds to the current ECM parts num-
Screen ber.
This screen displays the current ECM parts number. In the case of enforced update, you
Clicking the [Next] button advances to “2.9 New ECM can select all engine models.
Parts Number Search Screen.” ENGINE TYPE Select the engine type that corre-
To cancel former ECM parts number confirmation, click sponds to the current ECM parts num-
the [Cancel] button. ber.
In the case of enforced update, you
can select all engine types.
Select button Extracts the applicable OEM names
for the applicable ENGINE MODEL
and ENGINE TYPE, and provides
them for selection in the OEM NAME
box.
OEM NAME Select the OEM NAME from among
those that correspond to the selected
ENGINE MODEL and ENGINE TYPE.
ENGINE NUM- Engine Serial Number uploaded at
BER startup is displayed.
You cannot enter in this field except
the process that includes Engine S/N
change.
Back button Returns to “2.8 Current ECM Parts
Number Confirmation Screen.”
Next button Performs a check and then advances
to “2.10 New ECM Parts Number
2.9 New ECM Parts Number Search Screen Search Result Confirmation Screen.”
This screen is used to select the search conditions for
Parts Number. A message will appear if an error is discovered by the
Choose the option from [ENGINE MODEL] and check that is performed when the [Next] button is
[ENGINE TYPE], and then click the [Select] button. clicked.
Next, choose option from the [OEM NAME], and click
the [Next] button.
2.10 New ECM Parts Number Search Result 2.11 Reflashing ECM Parts Number
Confirmation Screen Confirmation Screen
This screen displays the search results. This screen displays the reflashing ECM parts number.
After checking the contents, click the [Next] button to After checking the contents, click the [Next] button to
advance to “2.11 Reflashing ECM Parts Number Con- perform a CD check and advance to “2.12 Switch Con-
firmation Screen.” firmation Screen 3.”
If the search results do not show the parts number you To return to “2.9 New ECM Parts Number Search
want, select the NEW ECM PARTS NUMBER INPUT Screen,” click the [Back] button.
check box, and then input the correct parts number.
(Be sure you input a compatible parts number.)
To return to “2.9 New ECM Parts Number Search
Screen,” click the [Back] button.
The following message will appear during the CD

check if a CD is not inserted or if the version does not
match.
Click the [OK] button to exit the program.
If program file name acquisition fails, advance to “6.

Recover Point.”
2.12 Switch Confirmation Screen 3 2.13 Switch Confirmation Screen 4
The switch confirmation screen is shown below. The switch confirmation screen is shown below.
Configure the switch settings as shown below. Configure the switch settings as shown below.
DATA SELECT switch: READ DATA SELECT switch: WRITE

ECM POWER switch: OFF ECM POWER switch: OFF
After configuring the switch settings, click the [Next] After configuring the switch settings, click the [Next]
button. button.
This will start data confirmation, display the message This will advance to “2.14 READY LED Confirmation
shown below, and advance to “2.13 Switch Confirma- Screen 1.”
tion Screen 4.”
2.14 READY LED Confirmation Screen 1
The selector LED confirmation screen is shown below.
After confirming that the LED is lit, click the [Yes] button
to advance to “2.15 Switch Confirmation Screen 5.”
If confirmation is not possible, click the [No] button to
return to “2.11 Reflashing ECM Parts Number Confir-
mation Screen.”
2.15 Switch Confirmation Screen 5 2.16 Reflashing Execution Confirmation
The switch confirmation screen is shown below. Screen
This screen displays a confirmation message for
reflashing.
Click the [OK] button to continue.
If you need to make changes, click the [Cancel] button
to return to “2.8 Current ECM Parts Number Confirma-
tion Screen.”
DATA SELECT switch: WRITE


button. This starts reflashing and displays the message shown
This will start data confirmation, display the message below.
shown below, and advance to “2.16 Reflashing Execu- After reflashing is complete, advance to “2.17 Switch
tion Confirmation Screen.” Confirmation Screen 6.”
Note:
One of the messages shown below will appear if an
error occurs during reflashing.
(Refer to “8. Error Code List.”)
Click the [Yes] button to return to “2.16 Reflashing Exe-

cution Confirmation Screen.”
The switch confirmation screen is shown below.
Click the [No] button to advance to “6. Recover Point.”

ECM POWER switch: OFF

button.
This will start data confirmation, display the message
shown below, and advance to “2.18 Switch Confirma-
tion Screen 7.”
2.18 Switch Confirmation Screen 7 2.19 READY LED Confirmation Screen 2
The switch confirmation screen is shown below. The selector LED confirmation screen is shown below.
After confirming that the LED is unlit, click the [Yes]
button to advance to “2.20 Switch Confirmation Screen
8.”
return to “2.18 Switch Confirmation Screen 7.”


button.
This will start communication with the selector and
advance to “2.19 READY LED Confirmation Screen 2.”
A message will appear if an error occurs during com-
munication. Refer to “7. Error Messages.”
2.20 Switch Confirmation Screen 8 2.21 Reflashing Result Confirmation Screen
The switch confirmation screen is shown below. This screen displays the parts number reflash result.
Configure the switch settings as shown below. Clicking the [Next] button displays the message shown
below.

button.
This starts data confirmation. After confirmation is com-
plete, advance to “2.21 Reflashing Result Confirmation
Screen.”
A message will appear if an error occurs during confir-
mation. Refer to “7. Error Messages.”
Check the content and click the [OK] button.
Note:
For [Normal] or [Campaign], this advances to “2.22
Final Result Confirmation Screen.”
For [Compulsory Reflash], this advances to “2.25
Engine Serial Number Confirm (in Compulsory
Reflash).”
2.22 Final Result Confirmation Screen 2.23 Switch Confirmation Screen 9
This screen displays the result of reflashing. The switch confirmation screen is shown below.
Clicking the [OK] button advances to “2.23 Switch Con- Configure the switch settings as shown below.
firmation Screen 9.”

button.
After configuring the power switch setting, click the

[Next] button to advance to “2.24 Cable Removal Con-
firmation Screen.”
2.24 Cable Removal Confirmation Screen 2.25 Engine Serial Number Confirm (in
Disconnect the cable which connects the selector to Compulsory Reflash)
ECM, and then click the [Next] button. Engine Serial Number entered in “2.9 New ECM Parts
This will advance to “2.26 Memory Clear.” Number Search Screen” is displayed.
After confirming the displayed content, click the [Next]

Battery Connection button to start downloading Engine Serial Number, and
the following display appears.
After download, the “Result Confirmation Screen”

appears.
2.26 Memory Clear
Perform memory clear in accordance with the instruc-
tions that are displayed.
Confirm the displayed content and click the [OK] but-

ton.
The following Process Confirmation Screen appears.
Clicking the [OK] button displays the following proce-
dure.
Select the process, and click the [Next] button.

the [Next] button is clicked. After memory clear is complete, click the [Clearing
memory is completed.] button to exit the program.
Set QR code. Advances to “3.8 Change Injector QR
Code” and displays “Change injector
QR code” screen.
Return to Process Returns to “2.1 Startup” and displays
menu “Process Menu” screen.
Finish EMPS pro- Returns to “2.23 Switch Confirmation
gram. Screen 9.” Perform termination
according to instructions on screens.
3. Injector Replacement
This section describes the procedure to change the QR
code during injector replacement.
3.1 Startup
Click the [Next] button to advance to the “Connection

Procedure” screen.

below.
Clicking the [OK] button displays the “Process Menu”

screen shown below.
Battery Connection

procedure.
After connection, clicking the [Next] button advances to
the next “3.2 User Authentication Screen.”

3.2.1 User Authentication Screen (Normal)

[Cancel] button.

tion.
conversion cable.
Panel].
ware].
WindowsXP
Battery Connection
Windows2000

Items Description
rate
exiting the tool.
WindowsXP
[Next] button.
Windows2000
ton.

nected.
This starts selector confirmation, and displays the mes-

sage shown below.
3.5 Selection Menu
[Next] button.

Selection Menu.”
mality is discovered. Click the [Return to User Authenti- Selection Item Descriptions
cation screen] button, and check the user ID. To
continue the process as is, click the [Continue process]
button. Process Menu The process selected in “3.1 Startup”
will appear.
Select ECM on the machine
tion Screen.”
tion Screen.”

power supply.


3.6 Selection Items Confirmation Screen
This screen shows the details of the settings configured
up to this point.
tion Screen 2.”
Selection Menu.”
Then, QR data is uploaded from ECM.

If the upload is successful, advance to “3.8 Change

Injector QR Code.”
One of the messages will appear if any abnormality is
discovered. Refer to “7. Error Messages.”


button.
sage shown below.
3.8 Change Injector QR Code
3.8.1 Process Confirmation Screen
After the upload, the location where you can find the
QR code to be entered appears, and then “Change
injector QR code” screen appears.
Clicking the [Close] button displays the next “Change

injector QR code” screen.
3.8.2 Change Injector QR Code Screen
1
3
4
10
5 6 11
Name
1. Engine Model field 7. Check button
2. Engine Serial Number field 8. Set button
3. QR data field 9. Cancel button
4. Cylinder No. selection field 10. Next button
5. QR Code entry field 11. Exit button
6. BCC entry field
Engine Model field Displays Engine Model uploaded from ECM.
Engine Serial Number field Displays Engine Serial Number uploaded from ECM.
QR data field Displays QR data uploaded from ECM.
Cylinder No. selection field Select or enter the number of cylinder that its QR code is changed.
QR Code entry field Enter the QR code.
BCC entry field Enter the BCC.
Check button Performs error check for entered data.
If error occurs, entered QR code and BCC will turn red.
If no error occurs, the [Set] button will be active.
Set button Sets the entered data to reflect it on the QR data fields on the top of the screen.
(‘Complete’ will be displayed in blue in the Check columns of QR data fields for the corre-
sponding cylinder No.)
Cancel button Discards the set QR codes in the QR data fields to return to the initial state.
Next button Advances to the next process (registration of entered data).
Exit button Quits EMPS program.
3.8.3 Procedure to Enter QR Code

1. Select or enter Cylinder No.
3. Enter the BCC.

After entering, [Check] button will become active.
2. Enter the injector QR code.
4. Click the [Check] button. 5. Click the [Set] button.

Error check for entered data will be performed. Entered data is reflected in the field on the top of
the screen, then the ”Change” field shows “Com-
Note: plete.”
If error for entered data occurred. [Cancel] button will also become active.
The letters in QR code and BCC fields will turn red. To return the status prior to change, click the [Can-
Enter them again. cel] button.
Note: To continue to enter other data, repeat the proce-

If no error for entered data occurred. dure from step 1.
[Set] button will become active. To complete, click the [Next] button.
6. Confirm download.
Clicking the [Next] button displays “Injector QR
Code Change Confirmation” screen.
The background color of changed cylinder has
turned light blue.
3.9 Injector QR Code Download
To correct the setting, click the [Back] button to

return to “Change Injector QR Code Screen.”
If the setting is OK, click the [Next] button to regis-
Check the switch status.
ter it into the ECM.
The following confirmation message will appear.

button.
Next button Starts to download the entered QR code.
3.9.1 Injector QR Code Download

The screen shown below will appear during download.
Clicking the [OK] button displays the “3.9 Injector

QR Code Download” screen.
3.10 Change Result Confirmation Screen 3.11 Switch Confirmation Screen 3
This screen displays downloaded QR code for confir- The switch confirmation screen is shown below.
mation.

Items Settings/Operation Performed DATA SELECT switch: READ
Next button Advances to “3.11 Switch Confirmation
Screen 3” to perform termination.
button.

3.12 Cable Removal Confirmation Screen 3.13 Memory Clear
Disconnect the cable which connects the selector to Perform memory clear in accordance with the instruc-
ECM, and then click the [Next] button. tions that are displayed.
This advances to “3.13 Memory Clear.”

dure.
Battery Connection
After memory clear is complete, click the [Clearing

4. Replace ECM (Same Model)
This section describes the procedure to replace the
ECM (or to make a copy) on the same model.
4.1 Startup
Select the [Replace ECM (Same Model)], and click the

[Next] button to advance to the next [Connection Pro-
cedure] screen.

below.

screen shown below.
Battery Connection 4.2 User Authentication Screen

[Cancel] button.

procedure.
Click the [Next] button to advance to “4.2 User Authen-
tication Screen.”

4.3 Connection Confirmation Screen Items Description
4.3.1 At the First Connection Next button Performs a check and then displays
This screen shows the connection status of the com- “4.4 Switch Confirmation Screen 1.”
One of the error messages will appear if an error is dis-
4.3.2 At the Reconnection After ECM Replacement

If you repeat upload or download (when reconnecting
after ECM replacement), you will start with this screen.
But you cannot change COM port and bit rate (bps).
4.3.3 PC Setting
tion.
conversion cable.
Panel].
Battery Connection 2. On [Control Panel], open [System].
ware].
WindowsXP

Items Description
rate
exiting the tool.
Windows2000 confirm the COM port to which the EMPS is con-
nected.

WindowsXP
Windows2000
[Next] button.

Selection Menu.”
ton.
button.

sage shown below.
4.5 Selection Menu
[Next] button.
Clicking the [Yes] button after checking the connection

of external power supply advances to “4.6 Selection
Items Confirmation Screen.”
Selection Item Descriptions If an external power supply cannot be connected, click
the [No] button to return to “4.5 Selection Menu.”
Clicking the [Help] button will display the message
Process Menu The process selected in “4.1 Startup” shown below.
will appear.
tion Screen.”
tion Screen.”

power supply.

up to this point.
tion Screen 2.”
Selection Menu.”
Clicking the [Yes] button after checking the voltage of

power supply advances to “4.6 Selection Items Confir-
mation Screen.”
If power supply cannot be confirmed, click the [No] but-
ton to return to “4.5 Selection Menu.”
shown below.
If the upload is successful, advance to “4.8 Current

ECM Parts Number Confirmation Screen.”
ECM POWER switch: ON 4.8 Current ECM Parts Number Confirmation
Screen
After configuring the switch settings, click the [Next] This screen displays the current ECM parts number.
button. Clicking the [Next] button advances to “4.9 New ECM
This starts selector confirmation, and displays the mes- Parts Number Search Screen.”
sage shown below. To cancel former ECM parts number confirmation, click
the [Cancel] button.
If response from the selector is normal, perform

uploading QR data.
4.9 New ECM Parts Number Search Screen Items Settings/Operation Performed
This screen is used to select the search conditions for Next button Performs a check and then advances
Parts Number. to “4.10 Switch Confirmation Screen
Choose the option from [ENGINE MODEL] and 3.”
[ENGINE TYPE], and then click the [Select] button.
Next, choose option from the [OEM NAME], and click A message will appear if an error is discovered by the
the [Next] button. check that is performed when the [Next] button is
To return to “4.8 Current ECM Parts Number Confirma- clicked.
tion Screen,” click the [Back] button.

sponds to the current ECM parts
number.
can select all engine models.
ENGINE TYPE Select the engine type that corre-
number.
and ENGINE TYPE, and provides
them for selection in the OEM NAME
box.
OEM NAME Select the OEM NAME from among
ENGINE MODEL and ENGINE
TYPE.
ENGINE NUMBER Engine Serial Number uploaded at
startup is displayed.
change.
After connecting other ECM, click the [OK] button.

“4.11 Connection Confirmation (After Connecting ECM)
and Reflash Mode Selection” will appear.


button.
After configuring the power switch setting, clicking the

[Next] button displays the message shown below.
4.11 Connection Confirmation (After
Connecting ECM) and Reflash Mode Selection
Name
1. Normal Update
2. Enforce Update
3. Campaign Update
Battery Connection
[Normal Update] (normal reflash)
Compatible parts number with reflashed parts number
is searched automatically and updated.
[Enforce Update] (compulsory reflash)
An arbitrary parts number is designated and updated.
Select this when reflashing was failed, or when reflash-
ing the parts number with no compatibility.
Specific password is necessary.
Campaign Update (Campaign)
This is performed at the campaign designated by man-
ufacturer. After reflashing, send the campaign log file
created to the administrator.
Select [Normal Update], [Enforce Update] (compulsory

reflash), or [Campaign Update], and then click the
[Next] button.
Connect the PC, selector, and ECM according to the the [Next] button is clicked.
procedure. Selected Option Settings/Operation Performed
After connection, click the [Next] button to proceed to
Normal Update Advances to “4.12.1 User Authentica-
the mode selection screen. tion Screen” – “For [Normal] or [Cam-
paign].”
Enforce Update Advances to “4.12.1 User Authentica-
tion Screen” – “For [Compulsory
Reflash].”
Campaign Update Advances to “4.12.1 User Authentica-
paign].”

below.

For [Normal] or [Campaign]
fields, click the [Next] button to advance to “4.12.2
[Cancel] button.
Check the content, and click the [OK] button to

advance to next.
For [Compulsory Reflash]

After entering information in the ID, PASSWORD, and
Enforce Update PASSWORD (Password for compul-
sory reflash) boxes, click [Next] to advanced to “4.12.2
[Cancel] button.

Battery Connection
4.13 Connection Confirmation Screen

This screen shows the connection status of the com- transmission bit rate (Bit/sec), click the [Next] button to
puter, selector, ECM, and power supply/battery. advance to “4.14 Switch Confirmation Screen 4.”
Power Supply Connection Selection Item Descriptions
Items Description
rate
exiting the tool.
One of the error messages will appear if an error is dis-

[Next] button.
If response from the selector is normal, advance to

“4.15 Selection Menu.”
ton.
button.

sage shown below.
4.15 Selection Menu
[Next] button.
Clicking the [Yes] button after checking the connection

of external power supply advances to “4.16 Selection
Items Confirmation Screen.”
Selection Item Descriptions If an external power supply cannot be connected, click
the [No] button to return to “4.15 Selection Menu.”
Process Menu The process selected in “4.1 Startup” shown below.
will appear.
tion Screen.”
tion Screen.”

power supply.

up to this point.
tion Screen 5.”
To change the settings, click the [Back] to return to
“4.15 Selection Menu.”
Clicking the [Yes] button after checking the voltage of

power supply advances to “4.16 Selection Items Confir-
mation Screen.”
If power supply cannot be confirmed, click the [No] but-
ton to return to “4.15 Selection Menu.”
shown below.



button.
This starts uploading Parts Number and displays the
message shown below.
4.18 Current ECM Parts Number Confirmation
Screen
This screen displays the current ECM parts number.
Clicking the [Next] button advances to “4.19 New ECM
Parts Number Search Screen.”
To cancel former ECM parts number confirmation, click
the [Cancel] button.
Then, injector QR code is uploaded. (The following

screen will be displayed briefly.)
If response from the selector is normal, advance to

“4.18 Current ECM Parts Number Confirmation
Screen.”
4.19 New ECM Parts Number Search Screen Items Settings/Operation Performed
This screen is used to select the search conditions for Next button Performs a check and then advances
Parts Number. to “4.20 ECM Replacement / Data
Choose the option from [ENGINE MODEL] and Confirmation.”
[ENGINE TYPE], and then click the [Select] button.
Next, choose option from the [OEM NAME], and click A message will appear if an error is discovered by the
the [Next] button. check that is performed when the [Next] button is
To return to “4.18 Current ECM Parts Number Confir- clicked.
mation Screen,” click the [Back] button.
4.20 ECM Replacement / Data Confirmation
Data obtained from ECM prior to changing connection
and from ECM currently connected are compared.
If data other than Parts Number is different, click the
[Back] button to return to “4.19 New ECM Parts Num-
ber Search Screen” and change the selection, or click
the [Cancel] button to quit the EMPS program and start
from the beginning again.
If the displayed contents are OK, click the [Next] button.

number.
can select all engine models.
ENGINE TYPE Select the engine type that corre-
number. Selection Item Descriptions
Cancel Performs termination, and quits EMPS pro-
gram.
and ENGINE TYPE, and provides Back Returns to “4.19 New ECM Parts Number
them for selection in the OEM NAME Search Screen.”
box.
Next Advances to “4.21 Switch Confirmation
OEM NAME Select the OEM NAME from among Screen 6.”
ENGINE MODEL and ENGINE
TYPE.
ENGINE NUMBER Engine Serial Number uploaded at
startup is displayed.
change.
4.21 Switch Confirmation Screen 6 4.22 Switch Confirmation Screen 7
The switch confirmation screen is shown below. The switch confirmation screen is shown below.
Configure the switch settings as shown below. Configure the switch settings as shown below.
DATA SELECT switch: READ DATA SELECT switch: WRITE

ECM POWER switch: OFF ECM POWER switch: OFF
After configuring the switch settings, click the [Next] After configuring the switch settings, click the [Next]
button. button. This will advance to “4.23 READY LED Confir-
This will start data confirmation, display the message mation Screen 1.”
tion Screen 7.” 4.23 READY LED Confirmation Screen 1
The selector LED confirmation screen is shown below.
return to “4.20 ECM Replacement / Data Confirmation.”
4.24 Switch Confirmation Screen 8 4.25 Reflashing Execution Confirmation
The switch confirmation screen is shown below. Screen
This screen displays a confirmation message for
reflashing.
Click the [OK] button to continue.
If you need to make changes, click the [Cancel] button
to return to “4.18 Current ECM Parts Number Confir-
mation Screen.”


button. This starts reflashing and displays the message shown
This will start data confirmation, display the message below.
shown below, and advance to “4.25 Reflashing Execu- After reflashing is complete, advance to “4.26 Switch
tion Confirmation Screen.” Confirmation Screen 9.”
Note:
One of the messages shown below will appear if an
error occurs during reflashing. (Refer to “8. Error Code
List.”)
Click the [Yes] button to return to “4.25 Reflashing Exe-

cution Confirmation Screen.”
Click the [No] button to advance to “6. Recover Point.”


button.
This will start data confirmation, display the message
tion Screen 10.”
4.27 Switch Confirmation Screen 10 4.28 READY LED Confirmation Screen 2
The switch confirmation screen is shown below. The selector LED confirmation screen is shown below.
return to “4.27 Switch Confirmation Screen 10.”


button.
This will start communication with the selector and
advance to “4.28 READY LED Confirmation Screen 2.”
A message will appear if an error occurs during com-
munication. Refer to “7. Error Messages.”
4.29 Switch Confirmation Screen 11 4.30 Reflashing Result Confirmation Screen
The switch confirmation screen is shown below. This screen displays the parts number reflash result.
Configure the switch settings as shown below. Clicking the [Next] button displays the message shown
below.

button.
This starts data confirmation. After confirmation is com-
plete, advance to “4.30 Reflashing Result Confirmation
Screen.”
A message will appear if an error occurs during confir-
mation. Refer to “7. Error Messages.”
Check the content and click the [OK] button.

This advances to “4.31 Engine Serial Number Confirm”
screen.
4.31 Engine Serial Number Confirm
Engine Serial Number of ECM prior to changing con-
nection will be displayed.
Confirm the displayed content and click the [OK] button

to advance to “4.32 Injector QR Code Change Confir-
mation Screen” screen.
After confirming the displayed content, click the [Next]
button to start downloading Engine Serial Number, and 4.32 Injector QR Code Change Confirmation
the following display appears. Screen
QR code uploaded from ECM prior to changing con-
nection will be displayed.
After download, the “Result Confirmation Screen”

appears.
Clicking the [Next] button starts to download the injec-
tor QR code.
4.33. Result Confirmation Screen
This screen displays the result of reflashing.
After download, the confirmation screen appears.
Clicking the [OK] button advances to “4.34 Switch Con-

firmation Screen 12.”
Click the [Next] button to advance to “4.33. Result Con-

4.34 Switch Confirmation Screen 12 4.35 Cable Removal Confirmation Screen
The switch confirmation screen is shown below. Disconnect the cable which connects the selector to
ECM, and then click the [Next] button.
DATA SELECT switch: READ Battery Connection


button.

4.36 Memory Clear

dure.

5. Factory Setting
This section describes the procedure to set the injector
QR code of connected ECM back to the factory setting
data.
5.1 Startup
Select the [Factory setting], and click the [Next] button

to advance to the next Connection Procedure screen.

below.

screen shown below.
Battery Connection 5.2 User Authentication Screen

[Cancel] button.

procedure.
After connection, clicking the [Next] button advances to
“5.2 User Authentication Screen.”

tion.
conversion cable.
Panel].
ware].
WindowsXP
Battery Connection
Windows2000

Items Description
rate
exiting the tool.
WindowsXP
[Next] button.
Windows2000
ton.

nected.

sage shown below.
5.5 Selection Menu
[Next] button.

Selection Menu.”
mality is discovered. Click the [Return to User Authenti- Selection Item Descriptions
button. Process Menu The process selected in “5.1 Startup”
will appear.
tion Screen.”
tion Screen.”

power supply.


5.6 Selection Items Confirmation Screen 5.7 Switch Confirmation Screen 2
This screen shows the details of the settings configured The switch confirmation screen is shown below.
up to this point.
tion Screen 2.”
Selection Menu.”


button.
This obtains Parts No. and factory setting data, and
advances to “5.8 Enter Engine Serial Number.”
5.8 Enter Engine Serial Number 5.9 Factory Setting Data Screen
Enter the serial number of the engine on which con- QR code uploaded from ECM and factory setting data
nected ECM is installed. are compared.
Clicking the [Next] button displays the following confir-

mation message.
Clicking the [OK] button displays “5.10 Injector QR

Code Download.”
5.10 Injector QR Code Download 5.11 Download Result Confirmation
The switch confirmation screen is shown below. This screen displays the result of download.


button.
below, and starts to download the factory setting data
of injector QR code to ECM.
5.12 Switch Confirmation Screen 3 5.13 Cable Removal Confirmation Screen
The switch confirmation screen is shown below. Disconnect the cable which connects the selector to
ECM, and then click the [Next] button.
This advances to “5.14 Memory Clear.”

ECM POWER switch: OFF Battery Connection

button.

5.14 Memory Clear

dure.

6. Recover Point
When data exchange with the selector is not performed correctly, you can select the point from which to continue the
procedure.
The procedure that can be continued depends on where the communication error was generated.
Items Description
Continue the procedure from Connection Confirmation Returns to “Connection Confirmation Screen” in each section.
screen.
Continue the procedure from Selection Menu screen. After the Switch Confirmation Screen is displayed, returns to
“Selection Menu” in each section.
Continue the procedure from Current ECM Parts Number After the Switch Confirmation Screen is displayed, returns to “Cur-
Confirmation screen. rent ECM Parts Number Confirmation Screen” in each section.
Continue the procedure from confirmation process after After the Switch Confirmation Screen is displayed, returns to
reflashing. “Switch Confirmation Screen 7” in each section.
To continue, select a process and then click the [Continue] button.

For some processes, a switch confirmation screen will appear.
Put switch settings back according to the following screens, and then click the [Next] button.
Switch Confirmation screen for “Continue the procedure from Selection Menu screen.”
Switch Confirmation screen for “Continue the procedure from Former ECM Parts Number Confirmation screen.”
Switch Confirmation screen for “Continue the procedure from confirmation process after reflashing.”
To exit the program without continuing, click the [Can-

cel] button.
After the message shown below appears, click the [OK]
button to exit the program.
7. Error Messages
7.1 Startup Errors (for Sections 2.1, 3.1, 4.1, 5.1)
Depending on the setup and operating environment, any one of the following error messages may appear during
startup.
Error Type Error Messages Description Response

Operating The system is not Reinstall the system.
environment ready because oper-
setting error ating environment
setting is not correct.
CD-ROM error CD-ROM drive cannot Check the CD-ROM drive.

be found.
No CD is inserted in Insert the Data CD into the

the CD-ROM drive. CD-ROM drive.
CD-ROM read CD-ROM read error Check the CD-ROM drive and
error Data CD. Contact your admin-
istrator if there is no fault.
Data read CD-ROM data read Check the CD-ROM drive and
error error Data CD. Contact your admin-
istrator if there is no fault.
7.2 User Authentication Errors (for Sections 2.2, 3.2, 4.2, 5.2)
One of the following error messages appear if the ID and/or password is not input, or if the input is incorrect.

No input ID not input. Enter your ID.
Password not input. Enter your password.
Incorrect pass- Password is wrong. Enter your correct password.

word
No input Password for compul- Enter the password for com-

sory reflash not input pulsory reflash.
Incorrect pass- Password for compul- Enter the correct password for
word for com- sory reflash is wrong. compulsory reflash.
pulsory
reflashing
Password for compul- Obtain the correct password

sory reflash has for compulsory reflash from
expired. your administrator .
OEM not OEM not selected Select OEM name.

selected

Database read Service address is not Check the Data CD. Contact
error found in the database. your administrator if there is no
fault.
7.3 Connection Confirmation Errors (for Sections 2.3, 3.3, 4.3, 5.3)

COM port COM port is not input. Enter the COM port.
COM port input value Enter the correct COM port.

is not correct.
COM port communi- Check if COM port operates

cation error properly.
Last process Last process continu-

check ation confirmation.
Click the [Yes] button
to advance to “2.8 —
Current ECM Parts
Number Confirmation
Screen.”
This message
appears to confirm
deletion when the
[No] button of the —
above message box
is clicked.
7.4 Switch Confirmation 1 Errors (for Switch Confirmation 4 in Sections 2.6, 3.6, 4.6, 5.6, 4.14)
One of the following messages will appear if any abnormality is discovered.

Communica- Serial number trans- Click the [OK] button to exit the
tion with the mission failure process, and then check the
selector selector.
Communication error Click the [OK] button to exit the

process, and then check the
selector. If the error occurs
again, contact the administra-
tor.
Response Response from the Click the [OK] button to exit the
from selector selector is incorrect. process, and then check the
selector.
7.5 Switch Confirmation 2 Errors (for Switch Confirmation 5 in Sections 2.7, 3.7, 4.7, 5.7, 4.17)
One of the following messages will appear if any abnormality is discovered.

Wrong current Check of current parts Click the [OK] button to return
parts number number to “Selection Menu” in each
section.
Clicking the [Cancel] button
displays a message to confirm
exiting of the program.
Exit confirma- Confirmation of sys- Click the [OK] button on the

tion tem termination message to exit the program.
Click the [Cancel] button to
return to “Selection Menu” in
each section.
Communica- Parts Number trans- Click the [OK] button to exit the
tion with the mission failure process, and then check the
selector selector.
Service Service address does Click the [Yes] button to

address not correspond. search again. Check the Data
CD. If the error occurs again,
contact the administrator.

Parts Number Parts Number cannot Click the [Yes] button for inte-
acquisition be obtained. grated confirmation process.
To cancel the process, click
the [No] button.
Execution confirma-
tion of integrated con-
firmation process if
clicking the [Yes] in —
the massage above.
Parts Number cannot Perform the compulsory

be obtained even reflash. If this message
after the integrated appears in the compulsory
confirmation process. reflash process, ECM may be
damaged.
7.6 New ECM Parts Number Search Screen (2.9, 4.19) Errors

Input check ENGINE MODEL Select ENGINE MODEL and/
and/or ENGINE TYPE or ENGINE TYPE.
is not selected.
OEM NAME is not Select the OEM NAME.

selected.
ENGINE NUMBER is Enter the ENGINE NUMBER.

not input.

Search error Parts number search Click the OK button and follow
failed. the next screen.
Parts Number entered Confirm the Parts No. and

for compulsory reflash enter it again.
is not found.
Parts number entered Confirm the Parts No. and

is not compatible with enter it again.
current Parts Number.
CD-ROM CD-ROM read error Check the CD-ROM.
CD-ROM cannot be Check the CD-ROM.

found.
7.7 Reflashing Execution Confirmation Screen (4.16, 4.25) Errors

Incorrect parts Command error dur- Click the [Yes] button to
number ing reflashing advance to “6. Recover Point.”
To cancel, click the [No] but-
ton.
This message Click the [OK] button to return

appears when the to “User Authentication
[No] button is clicked Screen.”
on the above mes-
sage.
7.8 Other Common Error

Communica- Communication error Click the [OK] button, switch
tion error at data transmission the selector to continue or exit
the process.
Confirmation Switch status is incor- Check the switch status of

of Switch rect. selector.
Campaign Campaign log file out- Check the HDD has enough
put error free space, and perform the
process again.
Campaign log file out- Check the HDD has enough

process again.
Campaign log file out- Check the HDD has enough

process again.
8. Error Code List
Start-up
Type Code Message Description
0001 Operating environment setting error Work folder acquisition
Reinstall the EMPS.
If the error occurs again, contact the administrator.
0002 Operating environment setting error Working folder does not exist.
Reinstall the EMPS.
0003 Operating environment setting error INI file does not exist.
Reinstall the EMPS.
0004 Operating environment setting error INI file invalid
Reinstall the EMPS.
Connection Command Screen

0005 The CD-ROM drive does not exist. No CD drive
0006 The CD cannot be read. CD read failure
0007 The CD has not been inserted. Insert the CD and click Retry but- CD insertion retry
ton.
0008 Data read error MDB file copy failure
Check the CD and CD drive.
0009 Data read error CD version file copy failure
0010 Data read error CD version file read failure
0011 Data read error MDB Open failure
Mode Select Screen

0012 Service address of OEM master cannot be obtained. OEM master service address read failure
User Authentication Screen

0013 Enter your ID. ID input
0014 Enter your PASSWORD. Password input
0015 Enter the PASSWORD for compulsory reflash. Password for compulsory reflash input
0016 ID and PASSWORD are invalid. ID + Password
0017 The PASSWORD for compulsory reflash is invalid. Password for compulsory reflash analysis
0018 The PASSWORD for compulsory reflash is invalid. Password for compulsory reflash and ID
0019 The PASSWORD for compulsory reflash has expired. Password for compulsory reflash expiration
date
0020 Service address of OEM master cannot be obtained. OEM master service address read failure
OEM Manufacturer Selection Screen
0021 Select the machine's manufacturer and click “OK.” Select OEM
Connection Confirmation Screen

0022 Enter the COM port. Port input
0023 Select transmission bit rate. Transmission bit rate selection
0024 Setting of COM port is invalid. Input port invalid digit number
0025 Setting of COM port is invalid. Input port invalid number
0026 Communication setting is invalid. Invalid communication setting
0027 Process was terminated last time (P_DATE). Do you want to con- Previous file exits.
tinue?
0028 Previous ECM Parts Number information will be deleted. Is it Previous file deletion confirmation
OK?
0177 Setting of COM port is invalid. Invalid port (communication setting)
Selector S/N Reading (1st time)

0029 Selector S/N Request cannot be sent. Selector S/N request failure
0030 This is unconfirmed selector. Unconfirmed
Check the selector.
0031 User ID does not correspond to selector S/N. User ID verification
Confirm user ID again.
0032 Communication error Incorrect number of digits in S/N
0033 Communication error Command error (receiver)
0034 Communication error BCC error (receiver)
0035 Communication error Command error reception
0036 Communication error BCC error reception
0037 Communication error Time-out error reception
0038 Communication error Other error reception
0039 Communication error Communication error (interrupt signal)
0040 Communication error Communication error (frame)
0041 Communication error Communication error (port overrun)
0042 Communication error Communication error (receive buffer over-
If the error occurs again, contact the administrator. flow)
0043 Communication error Communication error (parity)

0044 Communication error Communication error (the send buffer is full)
0045 Communication error Communication (DCB)
0046 Communication error Communication other error
0047 Communication error No response from selector
Former Parts No. Reading (1st time)

0048 ECM Parts Number Request cannot be sent. Parts number request failure
0049 Communication error Invalid number of digits for Parts No.
0050 Record of current Parts No. does not exist. Either former or current code does not exist.
The part number will be confirmed again. Clicking the [OK] button
returns to Selection Menu.
0051 Record of current Parts No. does not exist. Record acquisition error
The part number will be confirmed again. Clicking the [OK] button
returns to Selection Menu.
0052 Service address does not correspond. Do you want to search Service address retry
again?
0053 ECM Parts Number Request cannot be sent. Parts number request failure of service
address retry
0054 Current ECM Parts Number cannot be obtained. Execute an integrated process?
Do you want to execute an integrated confirmation process?
0055 Integrated confirmation process takes about 60 minutes. 60-minute process execution confirmation
Do you want to execute this process?
0056 Current ECM Parts Number could not be obtained. 60-minute process result error
This ECM needs compulsory reflash.
If the ECM Parts Number cannot be obtained even after compul-
sory reflash, the ECM may be damaged.
Program will be ended.
0064 Communication error Communication error (frame)

0066 Communication error Communication (receive buffer overflow)
0067 Communication error Communication error (parity)
0068 Communication error Communication (the send buffer is full)
0069 Communication error Communication error (DCB error)
New ECM Parts Number Search Screen

0072 Select “ENGINE MODEL”, “ENGINE TYPE” from pull-down menu Engine model selection
respectively, and click “Select” button.
0073 Select “ENGINE MODEL”, “ENGINE TYPE” from pull-down menu Engine type selection
respectively, and click “Select” button.
0074 Select “OEM NAME” from pull-down menu. Select OEM
0075 Enter the six-digit number into the “ENGINE NUMBER” field. Engine number input
0076 ECM Parts Number cannot be found. Appropriate new Parts No. does not exist.
New ECM Parts Number Search Confirmation Screen

0077 Enter new ECM Parts Number. New Parts No. input
0078 Record of former ECM Parts No. to be reflashed compulsorily No new record for compulsory reflash
does not exist.
0079 ECM Parts Number is not compatible No compatible code exist.
0080 Enter search condition for ECM Parts Number. OEM refined selection
0081 New ECM Parts Number cannot be identified. Refinement is not possible.
Rewriting Result Confirmation Screen

0082 The CD cannot be read. CD cannot be read.
0083 The CD has not been inserted. Insert the CD and click Retry but- CD insertion retry
ton.
0084 The CD, which is inserted, may be different from one used to CD version cannot be obtained.
start this program, or may be damaged.
Program will be ended in this status. Check the CD and start the
program again to restart the process.
0085 Setting of the program file does not exist. Program file cannot be obtained for this
Reflash cannot be processed. Select again. record.
0086 The CD, which is inserted, may be different from one used to Program file cannot be decompressed.
start this program, or may be damaged.
Program will be ended in this status. Check the CD and start the
program again to restart the process.
READY LED (ON)
0087 Check the switch status. LED does not come on.
Rewriting Initialization Process

During execution
0088 Reflash error Being processed (all)
Do you want to try reflash again?
0089 Reflash error Invalid startup parameter (all)
0090 Reflash error Thread startup failure (all)
0091 Reflash error Unknown
At CALL BACK
0092 Reflash error No response from rewriting module
0093 Reflash error Port open error (all)
0094 Reflash error Communication (all)
0095 Reflash error Time out (all)
0096 Reflash error Flash memory cannot be erased with boot
Do you want to try reflash again? mode (at initializing only)
Rewriting Reflashing Process

During execution
0099 Reflash error Inconsistent execution state (at writing and
Do you want to try reflash again? verifying)
At CALL BACK
0104 Reflash error User program file cannot be found (at writing
Do you want to try reflash again? and verifying)
0105 Reflash error Invalid user program file (at writing and veri-
Do you want to try reflash again? fying)

0106 Reflash error No data to be written to flash memory (at
Do you want to try reflash again? writing and verifying)
0107 Reflash error Close (at writing and verifying)
0111 Reflash error Writing (at writing only)
Rewriting Verification Process

During execution
0114 Reflash error Inconsistent execution state (at writing and
Do you want to try reflash again? verifying)
At CALL BACK
0119 Reflash error User program file cannot be found (at writing
Do you want to try reflash again? and verifying)
0120 Reflash error Invalid user program file (at writing and veri-
Do you want to try reflash again? fying)
0121 Reflash error No data to be written to flash memory (at
Do you want to try reflash again? writing and verifying)
0122 Reflash error Close (at writing and verifying)
0126 Reflash error Verification (at verification only)
READY LED (OFF)
0128 Check the switch status. LED not off
Selector S/N Reading (2nd time)

0129 Selector S/N Request cannot be sent. Selector S/N request failure
0130 Communication error Incorrect number of digits in S/N
0131 The device, which is different from one used to read the ECM Differ from the first time.
Part Number, is connected.
This ECM cannot operate properly. Do you want to try the pro-
cess again?
0132 Process will be terminated. Abort
Connect the selector correctly and try again.
0140 Communication error Communication error (frame error)
0143 Communication error Communication error (parity error)
0145 Communication error Communication error (DCB)
New Parts No. Reading (2nd time)
0148 ECM Parts Number Request cannot be sent. Parts number request failure
0149 Communication error Invalid number of digits for Parts No.
0150 Reflashed Parts Number does not correspond to the entered/ Differ from the entry value
selected Parts Number.
0151 Service address does not correspond. Do you want to search Service address retry
again?
0152 ECM Parts Number Request cannot be sent. Parts number request failure of service
address retry
0153 Current ECM Parts Number cannot be obtained. Integrated confirmation process
Do you want to execute an integrated confirmation process?
0154 Integrated confirmation process takes about 60 minutes. 60-minute process execution confirmation?
Do you want to execute this process?
0155 Current ECM Parts Number could not be obtained. 60-minute process result
If the ECM Parts Number cannot be obtained even after compul-
sory reflash, the ECM may be damaged.
Program will be ended.
0163 Communication error Communication error (frame error)
0166 Communication error Communication error (parity error)
0168 Communication error Communication error (DCB)
Campaign
0171 Campaign log could not be output. Campaign decoding error
0172 Campaign log could not be output. Campaign file coupling error
0173 Campaign log could not be output. No file being coupled for campaign
0175 Campaign log could not be output. Encryption error
0176 Desktop folder could not be obtained. Desktop cannot be obtained.
0177 Setting of COM port is invalid. Desktop cannot be copied.
Others
0178 Do you want to read the Parts No. and QR data from a file? Read confirmation
(If you select “No,” data will be read from ECM.)
0179 Download has not been completed successfully. Download failure
Perform termination, and restart the process from the beginning.
0180 Engine Serial Number has not been entered. No Engine Serial Number is entered.
0181 Entered Engine S/N does not correspond to connected ECM. No appropriate data exists in DB.
0183 Failed to upload. Do you want to continue the later process? Process continuation confirmation
0184 Failed to upload. Process exit confirmation
Perform termination, and restart the process from the beginning.
0185 QR data has not been set. (The item “Check OK” does not exist.) No QR data is entered.
0186 Error is found in setting data. QR data is incorrect.
0187 Do you want to start the registration of injector QRMSG to be Registration confirmation
changed?
0188 Do you want to continue the change process for injector? Process continuation confirmation
(If you select “No,” the process will be ended.))
0189 Replace the ECM, and then click the OK button. Direction to replace ECM
0190 Engine Serial Number has not been changed. S/N check
Do you want to continue this process?
(If you continue, data read from ECM will be used.)
0191 Uploaded QR data does not exist. QR data does not exist.
0192 Do you want to start downloading injector QR code? Confirmation of starting process
0193 Do you want to cancel the process, then return to Process Menu? Cancel of QR setting screen
0194 Setting process for injector will be continued. Confirmation after reflashing
0195 Changed QR code does not exist. QR code does not exist.
0196 Connected ECM is blank ECM. Quit the EMPS program and con- In case that all of uploaded QR data are “0.”
nect other ECM. Or perform the reflashing process.
0197 Connected ECM is blank ECM. In case that all of uploaded QR data are “0.”
Do you want to continue the replacement process for injector?
0198 Connected ECM does not correspond to EMPS. Perform reflash. In case of blank ECM
0199 Current ECM Parts Number could not be obtained. Failed to obtain ECM Parts Number.
Return to Process Menu.
0200 Connected ECM corresponds to the engine. In case that error occurred in model check
while setting back to the factory setting.

0201 Data corresponding to Engine S/N of connected ECM does not In case that error occurred in model check
exist. while setting back to the factory setting.
0202 The ECM prior to changing connection does not correspond to ECM compatibility error
the current ECM.
Return to the previous screen to change selection items. Or
restart the process from the beginning.
0203 There is injector on which no QR code is set. (QR code setting In case that injector QR code has not been
value remains “0.”) set yet.
How to Use Breaker Box

Breaker box inspection procedure Important:
When inspecting or measuring the voltage and
The breaker box is a tool to easily check open or short
continuity of ECM, be sure to use a adapter har-
circuit in connector pin and harness between ECM and
ness which is appropriate to the breaker box and
each sensor or actuator, which used to be difficult to
the inspected machine
check. Voltage and continuity on pins of ECM can be
measured through breaker box using digital multi-meter • Before inspection and measurement of ECM
(5-8840-2691-0). If a scan tool is also used, more pre- are performed, confirm the pin position. Other-
cise inspection and service can be performed. wise the ECM may get damaged.
Note:
The pin No. of ECM in diagnostic procedure matches
with the pin No. of breaker box.
1 2
A
TSWG0049
Name
1. Breaker box 2. Adapter harness
How to connect breaker box

Caution:
Be sure to turn off the key switch before the con-
nectors are disconnected.
1. Disconnect the ECM connector from ECM.

2. Connect the connector of adapter harness to ECM.
3. Connect the ECM connector to adapter harness.
4. Connect the adapter harness to breaker box.
3
1
TSWG0050
Name
1. Breaker box 3. ECM
2. Adapter harness 4. To machine-side harness
Caution: Example of use for breaker box

Take care with the following items when connect- 1. Inspection and measurement of voltage
ing the adapter harness to breaker box. Failure to
connect may damage the ECM. • Accelerator position sensor
• Connect the connector on adapter harness • Engine coolant temperature sensor
side to the connector of breaker box with the • Intake air temperature sensor etc.
same No. each other.
• When the connecting the connector, align the
cutouts of connector and breaker box each
other. 3
2
2
1
1
TSWG0052
Name
1. Breaker box
2. ECM
TSWG0051
3. Digital multimeter
Name
1. Connector No. (Adapter harness) 2. Inspection and measurement of resistance
2. Connector No. (Breaker box) • Crankshaft position sensor
3. Cutout • Camshaft position sensor
• SCV etc.
TSWG0053
Name
1. Breaker box
2. ECM
3. Digital multimeter
3. Inspection and measurement with oscilloscope

• Vehicle speed sensor signal
• Crankshaft position sensor signal
• Camshaft position sensor signal etc.
TSWG0054
Name
1. Breaker box
2. ECM
3. Oscilloscope
Caution:
During inspection and measurement, interference
of measurement lead on breaker box or mistaking
terminal to be measured may cause damage to
ECM or sensors. Work with extreme care.
Engine Control System

Description of function and operation for engine control (common rail) system
General and detailed description in engine • Idle speed control
control system The engine control system also has the following sys-
tem control functions other than engine control.
The engine control system is electronic control system
which maintains optimum combustion status of engine • QOS (Quick On Start) system
all the time according to operating conditions. It con- • Engine speed signal output
sists of the following components. • Self-diagnosis function
• Electronic control fuel injection system (Common • CAN (Controller Area Network) communication
rail type) (SAE J1939/21, SAE J1939/11)
• EGR (Exhaust gas recirculation)
System control schematic diagram

(*: Specifications vary depending on each machine. Refer to the machine’s manual.)
Engine control module (ECM)
Accelerator position sensor input

CAN communication Machine control unit
Basic fuel injection amount

Boost pressure sensor input
CKP sensor input
CMP sensor input
Correction
Engine coolant temperature correction ECT sensor input
Barometric Pressure
Fuel temperature boost pressure correction
Correction between cylinders
Q-key correction
QR correction *
Correction Vehicle speed sensor input
SCV opening
time determination Injector coil energizing time
Timing determination
Common rail pressure sensor
Common rail
Injector coil
SCV
Injector
Supply pump
Fuel tank
TSHK0001
About fuel injection correction
ECM calculates the basic injection amount based on
the signals from accelerator position sensor, boost
pressure sensor, CKP sensor, CMP sensor, etc. It reg-
ulates the opening/closing period of SCV or electric
conduction of injector according to the common rail
pressure, engine coolant temperature, etc. at this time,
Fuel flow limit (mm 3/st)

to correct the optimum injection timing and injection
amount.
About starting Q adjust

ECM performs starting Q adjust when the engine
speed is less than the starting Q threshold value at
engine starting.
Also, ECM cannot perform starting Q adjust or start the
engine when the engine speed is less than the lowest Barometric pressure kPa(psi)
speed that system can recognize, since it does not rec- highland
ognize engine rotation. TSWG0173
Control during overheat

In overheating, ECM begins to limit fuel flow when the
Engine speed (rpm)
engine coolant temperature exceeds 108°C (226°F),

for engine protection. It limits fuel flow further as the
engine coolant temperature goes up. Fuel flow is lim-
ited to a certain level at around 120°C (248°F).
Starting Q threshold enginespeed The system raises an alarm from 105°C (221°F) for
550
some machines. In addition to alarm, by reducing the
load to the machine, it enables to avoid such conditions
that the fuel flow is limited.
Minimum firing engine speed

60
30
System realization engine speed
TSWG0175
(226 )
100%
About high-altitude correction
ECM calculates the current altitude based on the baro-
Fuel fiow
metric pressure sensor signal.

It corrects the optimum fuel flow according to the alti- (248 )
tude etc. at this time.
(221 )
Engine coolant temperature
TSWG0169
Table of Input/Output
Injection control output

PCV (Pressure control valve)
Sensor input TWV (Injector) 4H:1-4 / 6H:1 - 6
Crankshaft position sensor
CMP sensor
Fuel temperature sensor
Engine coolant temperature sensor
Barometric pressure sensor
Common rail pressure sensor Actuator control output
Boost pressure sensor EGR DC motor
Accelerator position sensor 1, 2
Vehicle speed sensor
Oil pressure sensor
Boost temperature sensor
Intake air temperature sensor
ECM Relay, lamp control output
Glow relay
Starter cut relay
Diagnosis lamp
QOS indicator lamp
Switch input
Oil pressure lamp
Key switch (ON/Start)
Boost pressure lamp
Diagnostic switch
Idling control selector switch
Idling control switch (UP/DOWN)
EGR position sensor
Mode map switch 1, 2, 3
Memory clear switch Communication
Engine stop switch Speed signal (output to tachometer)
Starter relay Tech 2 signal
CAN (ECU on machine side)
TSHK0002
Electronic control fuel injection system (Common Injection pressure control

rail type) The system controls the injection pressure by control-
The engine control module (ECM) gets information, ling fuel pressure in common rail. It calculates the
such as engine speed, engine load, etc. (signals from appropriate pressure in common rail on the basis of
various sensors), and sends electrical signals, based engine speed, fuel injection amount, etc., and dis-
on the information, to the supply pump, injector, etc. in charges the proper amount of fuel by operating supply
order to properly control the fuel injection amount, pump resulting in pressure feed to common rail.
injection timing, etc. in each cylinder.
Injection timing control
Injection amount control This is substitute for a timer function. The system cal-
The system controls the injector, mainly based on the culates the fuel injection timing on the basis of mainly
signals from engine speed and accelerator opening engine speed, injection amount, etc. and controls the
angle or the designated speed of machine control unit, injector.
to maintain the optimum injection amount.
Injection rate control
To improve combustion in cylinders, the system injects
a little fuel (pre-injection) and ignites it at the beginning,
then perform the second injection (main injection) after
the first ignition. It controls these injection timing and
injection amount by operating the injector.
System schematic diagram
4HK1
Common rail Pressure

pressure sensor Common rail limiter
Electromagnetic Fuel filter

pump
Flow damper
Supply pump
Pre filter
Injector
Fuel tank
Each sensor
Accelerator, Boost pressure,
Engine coolant temperature, etc.
CMP sensor CKP sensor
TSHK0037
6HK1
Common rail Pressure

pressure sensor Common rail limiter
Electromagnetic Fuel filter
pump
Flow damper
Supply pump
Pre filter
Injector
Fuel tank
Each sensor
Accelerator, Boost pressure,
Engine coolant temperature, etc.
CMP sensor CKP sensor
TSHK0038
Fuel system
Fuel is supplied from fuel tank to supply pump, then
supplied to common rail after pressurized by the pump.
At this time, the system operates the suction control
valve (SCV) by the signal from ECM to control fuel
amount supplied to common rail.
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic pump 7. Injector
4. Pre-filter
EGR (Exhaust gas recirculation) On 4HK1-TC and 6HK1-TC machines, the EGR system
Exhaust Gas Recirculation system is abbreviated to has the check valve to stop backward flow of EGR gas
EGR system. It recirculates part of exhaust gas into and flows it in one way direction, leading to increase
intake manifold to mix an inert gas with intake air. This the amount of EGR.
leads to lower the combustion temperature to limit
emissions of nitrogen oxide (NOx).
It controls amount of EGR by opening/closing the EGR
valve installed between exhaust manifold and intake
manifold. It determines amount of EGR, based on the
engine speed and load rate on engine (fuel injection
amount), and operates the EGR valve to control the
amount of EGR.
The cooling system (EGR cooler) equipped on the
EGR gas passage allows to cool down high tempera-
ture EGR gas and mix it with new air to lower the com-
bustion temperature further, resulting in limiting NOx
effectively (Cooled EGR).
EGR control
ECM operates the motor according to engine speed,
engine load, etc. to control amount of EGR valve lift.
Amount of valve lift is detected by EGR position sensor.
The dark color area in the figure shows that the valve
lift amount is large, and the darkest color area shows
that the valve lift amount is almost 100%.
Accelerator position
No idle EGR
Engine speed
TSHK0066
EGR system schematic diagram
Outlet port of coolant Inlet port of coolant

EGR cooler
EGR valve
EGR valve position sensor

Exhaust

Boost pressure sensor
Intake air
Intake air temperature sensor
Engine speed
ECT sensor
Engine load
TSWG0005
Idling control UP
At warm-up operation, using the “Idling control selector While pressing the “Up” side of switch, the engine
switch” allows to control the lowest idling speed. Also, speed increases, resulting in increasing the idling
using the “Idling control selector switch” allows to auto- speed.
matically set the lowest idling speed to the optimum
value according to engine coolant temperature. DOWN
While pressing the “Down” side of switch, the engine
Note: speed decreases, resulting in decreasing the idling
Since specifications vary depending on each machine. speed. However, the idling speed does not decrease
Available functions also vary. below the lowest speed.
Idling control selector switch Note:

Using the “Idling control selector switch” allows to The engine speed controlled by idling control switch is
switch the idling control function. stored in ECM when the key switch is turned to OFF.
The same speed can be achieved at the next opera-
Idling control switch tion.
Using the “Idling control switch” allows to control the Speed limit control
idling speed.
Speed limit control means that the engine control mod-
Note: ule (ECM) controls fuel injection amount, based on
Refer to the machine’s manual for the locations of idling vehicle speed signal and engine speed, so that the
control selector switch and idling control switch. machine speed does not exceed the setting value.
The highest speed varies depending on engine model, The vehicle speed signal is sent from vehicle speed
machine specifications and warm-up condition of sensor to pulse matching box. The pulse matching box
engine. corrects the signal to match with the machine, and
sends it to ECM, meter, etc. The ECM recognizes the
engine speed by the signal from crankshaft position
(CKP) sensor.
Meter,
Other ECU
Engine Fuel injection control Pulse

matching box
Engine speed signal

Vehicle speed sensor
Check for speed limit control

To check whether the speed limit control on the
machine is active, check blinking of diagnosis lamp.
3. Diagnosis lamp illuminates for 15 seconds and
then blinks three times.
Engine speed output to tachometer
The engine control module (ECM) outputs the engine
speed pulse (4 pulses per engine revolution) as a
Key ON
switch tachometer output to tachometer. Tachometer shows
and
Engine the engine speed using the engine speed pulse sent
run OFF from ECM.
1 sec
1
Diag
lamp
0
1 sec
15 sec
3 times
TSWG0006
Note:
If it does not blink, the speed limit control is not active.
CAN Control unit

Engine speed Engine control communication Tachometer output
CKP sensor module (ECM) on machine side
Output from machine control unit by machine Tachometer
TSWG0119
Preheating control
QOS (Quick On Start) system
The ECM determines the period required for glow (pre-
glow, glow, after-glow), and operates the glow relay
and QOS indicator lamp. QOS system allows to make
the starting at cold weather easier and reduce white
smoke and noise at starting. When turning the key
switch to ON, the ECM detects the engine coolant tem-
perature by signal from engine coolant temperature
(ECT) sensor and changes the period for glow so that
the proper starting conditions can be achieved all the
time. Also, after-glow function allows to stabilize idling
immediately after starting.
Key switch (ON)

Battery
Glow relay
Glow plug
QOS indicator lamp
LCD or Lamp) Engine coolant temperature sensor
TSWG0007
Engine control module (ECM) ECM and components

About functions of ECM The ECM is designed to maintain the level of emission
as the emission control regulations and get a good per-
Note:
formance and fuel efficiency at the same time. The
Refer to the machine’s manual for the locations of
ECM monitors various functions of the engine through
ECM.
the sensors such as crankshaft position (CKP) sensor
etc.
ECM voltage
The ECM energizes standard voltage to various
switches and sensors. The resistance value of the
ECM is quite high so that the ECM can energize a volt-
age like this. The voltage actually applied to the circuit
is low, and it does not sometimes comes on even if the
test light is connected to the circuits. The voltmeter
usually used in a service shop may not indicate a cor-
rect reading because the input impedance is too low. A
digital multi-meter which has an input impedance of 10
MΩ (e.g. 5-8840-2691-0) should be used to get an cor-
rect reading of the voltage.
Electrically erasable programmable read only

memory (EEPROM)
TSWG0008
EEPROM has programs which is necessary for ECM to
control the operation of powertrain and information for
The ECM monitors the information sent from various calibration.
sensors all the time and controls each system of the If fault is found in the EEPROM, replace the ECM.
powertrain. The ECM performs the diagnostic function Examples of programs to control powertrain and infor-
of the system, detects operational problems of the sys- mation for calibration in ECM are the following items.
tem, gives a warning through diagnosis lamp to a driver • Engine model
and stores DTC (diagnostic trouble code). The area
• Engine number
where the trouble occurred can be identified by the
DTC to assist a mechanic to perform repair work. • ECM part number
The ECM sends the voltage of 5 V to supply the power • DTC
to various sensors or switches. The ECM controls the • Learning value for interval correction of cylinders
output circuits by controlling the ground or power sup-
• QR
ply circuit through a certain device.
• Q adjust
• Learning value for EGR correction
Precautions on ECM service work

Note:
• Be sure to use the ECM with the part number cor-
responding to the machine. Key switch
ON
• If performing welding on the machine, disconnect
the battery cable from the negative terminal
beforehand.
Key switch
The ECM is designed to sustain normal consumption of OFF
current relating to the operation of the machine. Cir-

10 sec
cuits should not be overloaded. In case of testing of
open and short circuits, the circuits of the ECM must
not be connected to the ground or be supplied with volt-
age except that there is such an instruction. Be sure to
use a digital multi-meter (5-8840-2691-0) when per-
forming the tests of these circuits. TSWG0176
Removal of ECM
2. Disconnect the battery cable from negative termi-
nal.
3. Remove the parts (relay etc.) around the ECM to
facilitate removal of it.
4. Disconnect the ECM connector from ECM. (81-pin,
40-pin connectors)
5. Loosen the installing bolts (nuts) and remove the
ECM.
Note:
Installation method and locations vary depending on
each machine. Refer to the machine’s manual.
Installation of ECM
Install the ECM in the reverse order of removal.
EGR valve position learning is required after replacing
the ECM.
1. Turn the key switch to “ON”.
2. Turn the key switch to “OFF”.
Failure to perform the EGR valve position learning may
result in detection of DTC for EGR.
About ECM power off

The power supply inside the ECM does not go off for
about 10 seconds after turning the key switch OFF. If
the ECM power needs to be off such as for memory
clear, wait for more than 10 seconds after turning the
key switch OFF.
Engine component location diagram
(Component location, its form and parts to be used vary depending on each machine.)
4HK1
13 12 11 10
7 6
9
1
2
8
3 4
TSHK0003
6HK1
13 12 11 10
7 6
2
8
3 4
TSHK0004
Name
1. Engine coolant temperature (ECT) sensor 8. Suction control valve (SCV)
2. Overheating switch 9. Fuel temperature (FT) sensor
3. Common rail pressure sensor 10. Boost temperature sensor
4. Engine oil pressure sensor 11. Boost pressure sensor
5. CKP sensor 12. Injector
6. CMP sensor 13. Glow plug
7. EGR valve
Supply pump SCV (suction control valve)
4HK1 4HK1
2 1
TSHK0005 TSHK0007
6HK1 6HK1
1
3
TSHK0006 TSHK0008
Name Name
1. SCV 1. SCV
2. Fuel temperature (FT) sensor
3. Feed pump
The SCV (suction control valve) is installed onto supply
pump section and controls pressure feed of fuel (dis-
The supply pump pressurizes fuel using engine output, charge amount) to common rail. The engine control
and pressure-feeds fuel to common rail. Supply pump module (ECM) regulates period of electric conduction
has also SCV (suction control valve), fuel temperature of SCV to regulate the fuel discharge amount.
(FT) sensor and feed pump.
Removal
Note: • Do not replace the SCV.
• If it is faulty, replace it as supply pump ASM.
vice manual.
4HK1 The fuel temperature (FT) sensor is installed onto the
supply pump, and the thermistor changes the resis-
tance according to the temperature. The resistance is
low when the fuel temperature is high, and is high when
the temperature is low. The engine control module
(ECM) energizes the voltage (5 V) to the FT sensor
through pull up resistance, and calculates fuel tempera-
ture based on change of voltage to use for various con-
trols such as supply pump control etc. If the resistance
is low (temperature is high), the voltage becomes low; if
the resistance is high (temperature is low), the voltage
becomes high.
Removal
• Do not replace the FT sensor.
• If it is faulty, replace it as supply pump ASM.
TSHK0127
6HK1
TSHK0110
Common rail
4HK1
TSHK0111
Fuel temperature (FT) sensor
1 2
TSHK0009
TSWG0011
6HK1 6HK1
4 4
3 3
1 2 1 2
TSHK0010 TSHK0010
Name Name
1. Common rail 1. Common rail
2. Common rail pressure sensor 2. Common rail pressure sensor
3. Pressure limiter 3. Pressure limiter
4. Flow damper 4. Flow damper
The common rail receives fuel from supply pump, holds The flow damper is installed onto outlet port to each
the common rail (fuel) pressure and distributes fuel to injector of common rail, limits pressure pulsation in
each cylinder. The common rail has common rail pres- common rail and prevents over-injected fuel from injec-
sure sensor, flow damper and pressure limiter. tor. When the flow damper operates, fuel supply to
injector is stopped.
Note:
For work procedure, refer to “Engine section” in the ser- Removal
vice manual. • Do not replace the flow damper.
• If it is damaged, replace it as common rail ASM.
Flow damper
4HK1 Pressure limiter
4HK1
3
4
1 2
1 2
TSHK0009
TSHK0009
6HK1 6HK1
4 4
3 3
1 2 1 2
TSHK0010 TSHK0010
Name Name
1. Common rail 1. Common rail
2. Common rail pressure sensor 2. Common rail pressure sensor
3. Pressure limiter 3. Pressure limiter
4. Flow damper 4. Flow damper
The pressure limiter operates to release the pressure in The common rail pressure sensor is installed onto com-
common rail when the pressure becomes extremely mon rail, detects fuel pressure in common rail, converts
high. the pressure into the voltage signal and sends it to
engine control module (ECM). Voltage becomes higher
Removal as pressure becomes higher, and lower as one does
• Do not replace the pressure limiter. lower. ECM calculates the actual common rail pressure
• If it is damaged, replace it as common rail ASM. (fuel pressure) based on the voltage signal sent from
sensors and uses it for fuel injection control etc.
Common rail pressure sensor Removal
4HK1 • Do not replace the common rail pressure sensor.
• If it is damaged, replace it as common rail ASM.
4HK1
1 2
TSHK0009
TSHK0121
6HK1 Engine coolant temperature (ECT) sensor
TSHK0112
TSWG0017
Injector The engine coolant temperature (ECT) sensor is

installed onto engine block, and the thermistor changes
the resistance according to the temperature. Resis-
tance is low at high engine coolant temperature and
high at low engine coolant temperature. The engine
control module (ECM) energizes the voltage (5 V) to
the ECT sensor through pull up resistance, and calcu-
lates engine coolant temperature based on change of
voltage to use for various controls such as fuel injection
etc. If the resistance is low (temperature is high), the
voltage becomes low; if the resistance is high (temper-
ature is low), the voltage becomes high.
Removal
• Disconnect the connector and remove it with
19mm-wrench
The injector is installed onto cylinder head section and

is controlled by engine control module (ECM) to inject
fuel. The ECM raises the voltage for operating injectors
internally, energizes to injector, and regulates period of
electric conduction of injector to control fuel injection 19mm
amount and injection timing.
Note:
vice manual.
TSHK0116
Installation 4HK1
• Apply Loctite 572 before installing it.
Tightening torque:
19.6 — 29.4 N⋅m {2 — 3kg⋅m/14 — 22 lb⋅ft}
Crankshaft position (CKP) sensor
10mm
TSHK0123
6HK1
TSWG0019
The crankshaft position (CKP) sensor is installed onto

flywheel housing and produces the CKP signal when
the convex portion of flywheel passes the sensor. The
engine control module (ECM) distinguishes the cylin- 10mm
ders by the CMP signal input from CMP sensor, deter-
mines the crank angle and uses it to control fuel
injection and calculate the engine speed. These con-
trols are performed, usually based on CKP signal.
However it is done by CMP sensor if the CKP sensor is
faulty.
Removal
TSHK0118
• Disconnect the connector, and remove the 10mm-
mounting bolt and sensor. Installation
Tightening torque:
14.7 — 24.5 N⋅m {1.5 — 2.5 kg⋅m/11 — 18 lb⋅ft}
Camshaft position (CMP) sensor 4HK1
4HK1
10mm
15
TSHK0124
TSHK0040 6HK1
6HK1
10mm
15
TSHK0117
TSWG0152 Installation
The camshaft position sensor is installed onto the rear • Apply a coat of engine oil to the O-ring.
of cylinder head and produces the CMP signal when Tightening torque:
the cam portion of camshaft passes the sensor. The 7.8±2 N⋅m {0.8±0.2 kg⋅m/69±18 lb⋅in}
engine control module (ECM) distinguishes the cylin-
ders by the CMP signal input from CMP sensor, deter-
mines the crank angle and uses it to control fuel
injection and calculate the engine speed. These con-
trols are performed, usually based on CKP signal.
However it is done by CMP sensor if the CKP sensor is
faulty.
Removal
• Scissors gear is installed to the cam gear of 6HK1
engine. When the cam gear has been removed,
ensure that the scissors gear is installed properly.
• Disconnect the connector, and remove the 10mm-
mounting bolt and sensor.
Engine oil pressure sensor 6HK1
27mm
TSHK0109
TSWG0067
Installation
The engine oil pressure sensor is installed near the
starter motor of the cylinder block; it detects engine oil Tightening torque:
pressure, converts the pressure into the voltage signal 41 N⋅m {4.2 kg⋅m/30 lb⋅ft}
and sends it to engine control module (ECM). Voltage
becomes higher as pressure becomes higher, and Accelerator position (AP) sensor
lower as one does lower. The accelerator position (AP) sensor is installed onto
machine console panel and supplies the voltage signal,
Removal which changes according to the accelerator volume
• Disconnect the connector and remove it with angle, to engine control module (ECM). The ECM cal-
27mm-wrench culates accelerator position by voltage signal and use it
for various controls such as fuel injection amount con-
4HK1
trol.
Note:
Refer to the machine’s manual for the location of accel-
erator position sensor.
Barometric pressure sensor
27mm
TSHK0122
TSWG0020
The barometric pressure sensor is installed onto the EGR position sensor
machine side and converts the barometric pressure
into voltage signal. The ECM calculates barometric
pressure by voltage signal and performs fuel injection
amount correction (high-altitude correction) etc. by
barometric pressure.
Note:
Refer to the machine’s manual for the location of baro-
metric pressure sensor.
Intake air temperature (IAT) sensor
TSWG0149
It is installed in EGR valve and detects the valve lift

amount of EGR.
Note:
Do not disassemble the EGR position sensor. If it is
faulty, replace it as EGR valve ASM.
Removal
4HK1
The intake air temperature (IAT) sensor is installed

onto the machine side and detects the temperature of
intake air for optimum fuel injection control.
Tightening torque:
10.8 — 16.3 N⋅m {1.1 — 1.7 kg⋅m/96 — 144 lb⋅in}
Note:
Refer to the machine’s manual for the location of intake
air temperature (IAT) sensor.
TSHK0125
6HK1
10mm
TSHK0113
TSHK0115
Installation
Tightening torque:
4 — 6 N⋅m {0.4 — 0.6 kg⋅m/35 — 53 lb⋅in}
TSWG0022
The boost pressure sensor uses the pressure hose

between the boost pressure sensor and intake pipe,
detects boost (intake air pressure), converts the pres-
sure into the voltage signal and sends it to engine con-
The boost temperature sensor is installed onto the
trol module (ECM). Voltage becomes higher as
EGR valve upstream side of intake manifold. The sen-
pressure becomes higher, and lower as one does
sor is thermistor type. The resistance in the sensor
lower. ECM calculates the boost (intake air pressure)
changes as the temperature changes.
based on the voltage signal sent from sensors and
uses it for fuel injection control etc. Removal
Removal • Disconnect the connector and remove it with
19mm-wrench
• Disconnect the connector, and remove the two
10mm-mounting bolts, hoses and sensor.
4HK1 DLC (data link connector)
19mm
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
TSHK0126
TSWG0023
6HK1
The DLC (data link connector) is a connector for com-
munication and connection between the external diag-
nostic device (scan tool) and each controller.
Note:
Refer to the machine’s manual for the locations of DLC.
19mm Diagnostic switch

The diagnosis switch shorts the DLC terminals No. 1
and No. 4 (or No. 5) to make the diagnosis lamp blink
to indicate DTC.
Note:
Refer to the machine’s manual for the locations and
form of diagnosis switch.
Memory clear switch

TSHK0114 The diagnosis switch and memory clear switch are
used to clear the DTC stored in ECM.
Installation
Note:
Tightening torque: Refer to the machine’s manual for the locations of
10.8 — 16.3 N⋅m {1.1 — 1.7 kg⋅m/96 — 144 lb⋅in} memory clear switch.
Diagnosis lamp Mode selector switch (1, 2, 3)

It indicates DTC by blinking after the diagnosis switch is The mode selector switch allows to operate at the
turned to ON. engine speed set by each mode.
Note: Note:
Refer to the machine’s manual for the locations of diag- Refer to the machine’s manual for the locations of
nosis lamp. mode selector switch.
Wiring diagram of engine control module (ECM)
(*: Refer to the machine’s manual for fuse capacity.)
4HK1
(15A)*
24
Engine stop switch 107 CKP sensor
47 106
Diagnostic lamp
6 108
Engine oil pressure lamp
17
Key switch
QOS indicator lamp 80

11 67 Engine oil
Boost temperature lamp 79 pressure sensor
(ON)
7
10 84 Engine coolant
temperature sensor
(50A)*
Glow relay
83
Fuel temperature
sensor
Glow plug
(60A)* 99
CMP sensor
98
100
Key switch
Main relay 21 87
40 82
(ST)
(30A)* Common rail

2 90
101 pressure sensor
5
(10A)*
94 U
EGR valve
93 V
(30A)* position sensor
92 W
2
(100A)*
Vehicle speed
19
Fuel pump relay sensor
121
Battery
(10A)*
Fuel pump Injector #1

119
ECM
M
Charge 117 Injector #4
lamp O/H lamp O/H switch
116
Generator
R Injector #3
L 120
Safty relay B terminal
E Sterter 118 Injector #2
R S S terminal SCV
B C B terminal 105
113
89
97
42
Accelerator
63 8 Tachometer
position
sensor 64
41
20 18
Barometric 61 37
pressure 71
sensor 60
Intake air 72
temperature 38 7 TOOL
sensor
72 52 1
Data link connector
Boost 95 4
pressure 91 5
sensor 109
Boost 74
temperature 81
sensor
43
U 111 62
EGR valve V
M 103 1
motor W 110
3
Memory clear switch 32 4
TSHK0011
6HK1
(15A)*
24 107 CKP sensor
Engine stop switch 106
47
Diagnostic lamp 6 108
80
Key switch
17
QOS indicator lamp 67 Engine oil
11 pressure sensor
79
(ON)
Boost temperature lamp

7
84 Engine coolant
10
temperature sensor
(50A)*
Glow relay 83 Fuel temperature

sensor
Glow plug 99
(60A)* CMP sensor
98
100
Main relay 87
Key switch
21
82
40 Common rail
(ST)
(30A)* 90
2 101 pressure sensor
5
(10A)*
94 U EGR valve
93 V position sensor
92 W
46
(100A)*
19 Vehicle speed
121
Injector #1
119
Battery
(10A)*
Fuel pump
114 Injector #2
ECM
M
Charge
117 Injector #3
116
Generator
R
L Injector #4
115
E Sterter Injector #5
120
R S S terminal
B C B terminal Injector #6
118
SCV
105
42 113
Accelerator
position 63 89
sensor 64 97
41
20 8 Tachometer
Barometric 61
pressure 71
sensor 60 18
37
Intake air 72
temperature
sensor
38 7 TOOL
Boost 95
52 1 Data link connector
pressure 91
sensor 109 4
5
Boost 74
temperature 81
sensor
43
U 111 62
EGR valve V 103
M 1
motor W 110
3
Memory clear switch
32 4
TSHK0036
Pin arrangement of engine control module (ECM)
TSWG0026
81-pin connector
Pin No. Terminal name Connection

1 PG-POWER GND
2 PS-+B Power supply
3 PG-POWER GND
4 PG-POWER GND
5 PS-+B Power supply
6 OS-DIAGL Diagnosis lamp
7 OS-BOOSTL Boost temperature sensor pilot lamp
8 — —
9 — —
10 OS-GLOWR Glow Relay
11 OS-GLOWL QOS indicator lamp

12 — —
13 — —
14 — —
15 — —
16 — —
17 OS-OILPL Engine oil pressure lamp
18 CC-CAN-H CAN-HIGH
19 IF-SPD Vehicle speed sensor signal
20 SG-SLD1 Accelerator position sensor 1 GND
21 OS-MAINR ECM main relay
22 — —
23 — —
24 IS-IGKEY Key switch ON signal
25 — —
26 — —
27 — —
28 — —
29 — —
30 — —
31 — —
32 IS-MEMCL Memory clear switch
33 — —
34 — —
35 — —
36 — —
37 CC-CAN-L CAN-LOW
38 CC-KW2000 Data link connector
39 — —
40 OS-MAINR ECM main relay
41 SG-5VRT1 Accelerator position (AP) sensor GND
42 SP-5V1 Accelerator position (AP) sensor power supply
43 PG-SIGN GND
44 — —
45 — —
46 IS-START Key switch start signal
47 ENGSTP Engine stop switch
48 — —
49 — —
50 — —
51 — —
52 IS-DIAG Diagnostic switch

53 — —
54 — —
55 — —
56 — —
57 — —
58 — —
59 — —
60 SG-5VRT2 Barometric pressure sensor, intake air temperature (IAT) sensor GND
61 SP-5V2 Barometric pressure sensor power supply
62 PG-SIGN GND
63 IA-ACCEL1 Accelerator position (AP) sensor 1 signal
64 IA-ACCEL2 Accelerator position (AP) sensor 2 signal
65 — —
66 — —
67 IA-OILPRESS Engine oil pressure sensor signal
68 — —
69 — —
70 — —
71 IA-BARO Barometric pressure sensor signal
72 IA-IAT Intake air temperature sensor signal
73 — —
74 IA-THBST Boost temperature signal
75 — —
76 — —
77 — —
78 — —
79 SG-5VRT3 Engine oil pressure sensor, fuel temperature sensor, engine coolant temperature
sensor GND
80 SP-5V3 Engine oil pressure sensor power supply
81 PG-CASE GND
40-pin connector

82 IA-PFUEL Common rail pressure sensor signal
83 IA-THL Fuel temperature sensor signal
84 IA-THW Engine coolant temperature sensor signal
85 — —
86 — —
87 SP-5V5 Common rail pressure sensor power supply
88 — —
89 IA-SCVLO SCVLO drive

90 IA-PFUEL Common rail pressure sensor signal
91 IA-BPRESS Boost pressure sensor signal
92 IA-EBMPOS3 EGR valve EGR position sensor W
93 IA-EBMPOS2 EGR valve EGR position sensor V
94 IA-EBMPOS1 EGR valve EGR position sensor U
95 SP-5V4 Boost pressure sensor power supply
96 — —
97 IA-SCVLO SCVLO drive
98 IF-CAMHAL Camshaft position (CMP) sensor signal
99 SP-CAMHAL Camshaft position (CMP) sensor power supply
100 SG-SLD5 Camshaft position (CMP) sensor, common rail pressure sensor shield
101 SG-5VRT5 Common rail pressure sensor GND
102 — —
103 OM-EBM2 EGR valve DC servomotor power supply input V
104 — —
105 OS-SCVHI SCVHI drive
106 IF-CRANK- Crankshaft position (CKP) sensor (−)
107 IF-CRANK+ Crankshaft position (CKP) sensor (+)
108 SG-SLD4 Crankshaft position (CKP) sensor shield
109 SG-5VRT4 Boost pressure sensor, engine coolant temperature sensor, fuel temperature sensor
GND
110 OM-EBM3 EGR valve DC servomotor power supply input W
111 OM-EBM1 EGR valve DC servomotor power supply input U
112 — —
113 OS-SCVHI SCVHI drive
114 OS-INJ5 Injector 2 (6H only)
115 OS-INJ6 Injector 4 (6H only)
116 OP-COM2 Injector power supply 2
(4H: No. 2, No. 3 cylinders/6H: No. 4, No. 5, No. 6 cylinders)
117 OS-INJ3 4H: Injector 4/6H: Injector 3
119 OS-INJ1 Injector 1
121 OP-COM1 Injector power supply 1
(4H: No. 1, No. 4 cylinders/6H: No. 1, No. 2, No. 3 cylinders)
Circuit diagram
(Refer to 1E-7, “About wiring diagrams, How to Use This Manual” for a way to read the diagram.)
Main relay circuit

(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)

21 E-57
Main relay
40 E-57
E-57
B+
2
(30A)*
E-57
B+
5
(MAIN)*
Battery
TSWG0027
4HK1
(100A)*
Starter
B
C
Battery
B
Generator
(15A)*
(60A)*
Starter for ECM control, glow circuit
Glow relay Starter relay Starter cut relay Main relay
(10A)*
1 H-22
5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START
10 E-57 Key switch 14 E-57
Glow Glow relay control

plug
Starter cut relay signal

TSHK0012
6HK1
(100A)*
Starter
B
C
Battery
B
Generator
(15A)*
(60A)*
Glow relay Starter relay Starter cut relay Main relay
(10A)*
1 H-22
5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START
Glow Glow relay control

plug
TSWG0028
Starter for safety relay, glow circuit
4HK1

(ON) (ST)
Br C
Key switch
ACC
B
START
OFF
ON
A
(ON) (ST)
BBr C
Safty relay
START
OFF
Glow relay control

ON
A
S
Starter
E-57
C
C
B
10
B
Glow
plug
Generator
Glow relay
B
L
(100A)*
(60A)*
H-22
B/W
H-1
5
1
1
(15A)*
Battery
TSHK0025
6HK1
Starter
B
Battery B
Generator
(100A)* L
(15A)* (60A)*
B C
Safety relay
L S
Glow
relay
A A
1 H-22
B Br C B ACC Br C
5 (ON) (ST) (ON) (ST)
B/W
OFF OFF
ON ON
START START
1 H-1
Key switch
10 E-57
Engine control
module (ECM)
Glow relay
control
Glow
plug
TSWG0068
CAN LOW CAN HIGH
Engine control
module (ECM)
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
CAN, GND, DLC circuits
1 FL-150 7 FL-150
DLC
Machine control unit
5 FL-150 4 FL-150
CAN HIGH CAN LOW

TSHK0013
(15A)*
A A
Meter
Machine trouble Boost Charge O/H lamp

Diagnosis Engine oil QOS indicator Tachometer
diagnosis monitor temperature lamp
lamp pressure lamp lamp
lamp
3 H-6
Indicator lamp, tachometer circuit
1 E-164
Machine O/H switch

control unit
CAN LOW CAN HIGH

Generator
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 8 E-57
Engine control
module (ECM)
Diagnosis Engine oil pressure QOS indicator Boost temperature

lamp control lamp control lamp control lamp control
Tachometer signal
CAN HIGH CAN LOW
TSHK0014
4HK1
Injector circuit
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31
Injector Injector Injector Injector

(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)
3 3
3 E-35 3 E-37 E-27 E-31
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

R L/Y L/R R W L L/W W
3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56
Engine control
Cylinder No. 3 Cylinder No. 2 Cylinder No. 1 Cylinder No. 4 module (ECM)
Feedback Feedback Feedback Feedback

B+ B+
TSHK0015
6HK1
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
Injector Injector Injector Injector Injector Injector

(Cylinder No. 5) (Cylinder No. 6) (Cylinder No. 4) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 3)
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Cylinder No. 5 Cylinder No. 6 Cylinder No. 4 Cylinder No. 2 Cylinder No. 1 Cylinder No. 3
Feedback Feedback Feedback Feedback Feedback Feedback

B+ B+
TSWG0031
SCV circuit
2 E-161
SCV
1 E-161
0.75 0.75
R/B R/W
1 H-6 2 H-6
97 E-56 89 E-56 105 E-56 113 E-56

Engine contorol
module (ECM)
B+
TSHK0016
sensor signal 5V 5V sensor signal
5V
CKP CKP Engine coolant Vcc

HIGH LOW Fuel temperature temperature sensor
signal signal sensor signal signal
108 E-56 107 E-56 106 E-56 19 E-57 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
engine oil pressure sensor circuit
3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
2 E-98 1 E-98
Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
* 3 E-90 Engine control

CAN LOW CAN HIGH module (ECM)
0.75
R
4 H-6 37 E-57 18 E-57
Vehicle
speed sensor A
Meter
Machine
control
unit
Engine CAN HIGH CAN LOW
coolant
temperature
gauge
Machine trouble
diagnosis monitor
CKP sensor, vehicle speed sensor, fuel temperature sensor, engine coolant temperature sensor,
TSHK0017
Engine control
module (ECM)
5V Boost pressure
sensor signal
5V
Boost temperature
sensor signal
74 E-56 109 E-56 91 E-56 95 E-56
15 H-20 17 H-20 16 H-20 8 H-20

Boost temperature sensor, boost pressure sensor circuit
0.75 0.75 0.75 0.75 0.75

B/R R/L R/L L R/W
2 E-163 1 E-163 1 E-75 2 E-75 3 E-75


TSWG0034
CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V Engine control
module (ECM)
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8
4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B
CMP sensor, common rail pressure sensor, EGR circuit
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1 E-112 2 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR position sensor/EGR motor
EGR valve
CMP sensor Common rail pressure sensor
TSHK0018
A A
Engine control
Accelerator Accelerator module (ECM)
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW

20 H-20 19 H-20 18 H-20
6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124
Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor
Accelerator position sensor, barometric pressure sensor, intake air temperature sensor circuit
TSHK0019
Key switch (ON)
(15A)*
Reguration
Idling selector Load advance Engine stop
mode Idle up Idle down Mode map Mode map Mode map
switch switch switch
switch switch switch switch 0 switch 1 switch 2
29 E-57 41 E-57 33 E-57 47 E-57 30 E-57 31 E-57 49 E-57 50 E-57 51 E-57

Idling selector switch, idle up switch, idle down switch, mode map switch circuit
Engine control
module (ECM)
Idling selector Load advance Reguration mode Engine stop Idle up Idle down Mode map Mode map Mode map
switch signal switch signal switch signal switch signal switch signal switch signal switch 0 signal switch 1 signal switch 2 signal
TSHK0142
Memory clear switch, engine stop switch circuit
(15A)*
Key switch (ON)
control unit
Machine
E-57
CAN HIGH CAN LOW

CAN HIGH
18
E-57
CAN LOW
37
Engine stop switch

A
E-57
47
Memory clear switch

A
E-57
32
B
B
TSWG0038
Engine harness location
4HK1
:Engine harness
13 12 11 10
7 6
9
1
2
8
3 4
TSHK0020
Name
1. Engine coolant temperature sensor 8. SCV
2. Overheating switch 9. Fuel temperature sensor
7. EGR position sensor
98003-428 SENSOR:BOOST PRESS
E80 E75
EGR VALVE 1 2 3
E113 0.75 0.75 0.75
R/L L R/W
SENSOR:COMMON RAIL 1 2 3 4
0.75 0.75 0.75 0.75
L G/Y G/W G /B
5 6 7 8
1 2 3
0.5 0. 5 0.5 0.75 0.75 0.75 0.75
L/W Br L L/W W/L W/B W/R
H94
1 2 3 4 INJECTOR
1.25 1.25 1.25 1.25
W R R W
5 6 7 8
0.75 0.75 0.75 0.75 E163
L L /R L /Y L / W
SENSOR:MAT(BOOST TEMP)
1 2
0.75 0.75
R/L B/R
1 1 2 3
5 0 . 7 5 0 .5 0 .5
B/W B /W V /W Y
GLOW PLUG(No.1) SENSOR:CAM ANGLE(G)

E112
H1
E161
1 2
1 2 SCV
0.75 0.75 1 2
0.75 0.75 R /W R /B
B/Y R /B 0 .5 0 .5
1 Y V /W
3 0.75
0.75 G SENSOR:NE.CRANK
R
SENSOR:WATER SWITCH:O/H E93 E98

SENSOR:FUEL TEMP
E90 E164 1 2
0.75 0.75
B /Y Y /G
1 2 3
0.75 0.75 0.75
B / Y L / Y W/ B
SENSOR:OIL PRESSRE
E76
1
5
B/W
H22
1 2 3 4
0.5 0.5 0.75 0.5
Y V/W B Y
5 6 7 8
0.5 0.75 0.75 0.75
V/W B/W R /B R /W
4 3 2 1 9 10 11 12
1.25 1.25 0.75 0.75 0.75 0.5
W R W/B L/ Y B /Y L
3 2 1 4 3 2 1 8 7 6 5
0.75 0.75 0.75 0.75 0.75 0.75 13 14 15 16
Y/ G R / W R / B G / Y G /W G /B 0.75 0.75 0.75 0.75
L L / R L/ Y L / W 0.5 0.5 0.75 0.75
6 5 4 8 7 6 5 Br L/W B/R L
12 11 10 9
0.75 0.75 0.75 0.75 0.75 17 18 19 20
G R W /L W /B W/R 0.75
R/L
H6 H8 H12 H20
TSHK0034
E75 E112
Terminal Terminal
Number Number
1 Boost pressure sensor GND 1 CMP shield
2 Boost pressure sensor Vout 2 CMP GND
3 Boost pressure sensor Vcc 3 CMP +
E76 E113
Terminal Terminal
Number Number
1 Engine oil pressure sensor GND 1 Common rail pressure sensor GND
2 Engine oil pressure sensor Vout 2 Common rail pressure sensor Vout
3 Engine oil pressure sensor Vcc 3 Common rail pressure sensor Vcc
E80 E161
Terminal Terminal
Number Number
1 EGR Vcc 1 SCV — Hi
2 EGR hall sensor W 2 SCV — Lo
3 EGR hall sensor V
E163
4 EGR hall sensor U
Terminal
5 EGR GND
Number
6 EGR motor W
1 Boost temperature sensor GND
7 EGR motor V
2 Boost temperature sensor +
8 EGR motor U
E164
E90
Terminal
Terminal Number
Number
1 Overheating switch
1 ECT GND
2 ECT + H1
3 ECT meter Terminal
Number
E93 1 Glow
Terminal
Number H6
1 Fuel temperature sensor GND Terminal
Number
2 Fuel temperature sensor +
1 SCV − Lo
E98 2 SCV − Hi
Terminal 3 Fuel temperature sensor +
Number
4 ECT meter
1 CKP +
5 —
2 CKP GND
H8 Terminal
Terminal Number
Number 14 Common rail pressure sensor GND
1 EGR hall sensor U 15 Boost temperature sensor +
2 EGR hall sensor V 16 Boost pressure sensor Vout
3 EGR hall sensor W 17 Boost pressure sensor GND
4 — 18 —
5 EGR motor U 19 —
6 EGR motor V 20 —
7 EGR motor W
H22
8 —
Terminal
Number
H12
1 Glow
Terminal
Number
H94
1 —
Terminal
2 —
Number
3 Injector power supply 2
5 OS-INJ3 signal/Injector #4
9 —
10 —
11 —
12 —
H20
Terminal
Number
1 CKP +
2 CKP GND
3 CKP shield
4 CMP +
5 CMP GND
6 CMP shield
7 ECT +
8 Boost pressure sensor Vcc
9 Engine oil pressure sensor Vcc
10 Engine oil pressure sensor Vout
11 Engine oil pressure sensor GND
12 Common rail pressure sensor Vcc
13 Common rail pressure sensor Vout
Cylinder head
E27 E31 E35 E37
H94 H94
(Male connector (Female connector on injector side)
on ECM side)
TSHK0044
6HK1
:Engine harness
13 12 11 10
7 6
2
8
3 4
TSHK0021
Name
1. Engine coolant temperature sensor 8. SCV
2. Overheating switch 9. Fuel temperature sensor
7. EGR position sensor
98013-710
1 2 3 4
0.75 1.25 1.25
G/B R R
5 6 7 8
0.75 0.75
L/R L/Y
H95
INJECTOR 2(#4.5.6 )
H94
INJECTOR 1(#1.2.3 )
1 2 3 4
0.75 1.25 1.25
L W W
5 6 7 8
1
5 0.75 0.75
B/W L/W G/R 1 2 3 4
0.75 0.75 0.75 0.75
L G/Y G/W G/B
H1 5 6 7 8
0.75 0.75 0.75 0.75
GLOW PLUG L/W W/L W/B W/R
E80
1 2
EGR VALVE
0.75 0.75
B /Y R /B
3 1 2 3
0.75 0.75 0.75 0.75
R R/L L R/W E93
1 2
0.75 0.75 SENSOR:FUEL TEMP
E90 B /Y Y /G
E75
SENSOR:WATER 1 2
SENSOR:BOOST PRESS 0.75 0.75
R /L B /R
E163
SENSOR:MAT(BOOST TEMP) 1 2
E164 0.75 0.75
R /W R /B
SWITCH:O/H
1
0.75 E161
G
SCV
1 2 3
0.5 0.5 0.5
L/W Br L
1 2 3
0 . 7 5 0 .5 0 .5
E113 B /W V /W Y
SENSOR:COMMON RAIL E112

SENSOR:CAM ANGLE(G)
1 2
1 2 3 0 .5 0 .5
0.75 0.75 0.75 E76 Y V /W
B / Y L / Y W/ B
E98
SENSOR:OIL PRESSRE
SENSOR:NE.CRANK
1 2 3 4
0.5 0.5 0.75 0.5
Y V/W B Y
5 6 7 8
0.5 0.75 0.75 0.75
V/W B/W R/B R/W
4 3 2 1 9 10 11 12
1.25 1.25 0.75 0.75 0.75 0.5
W R W/B L/ Y B/Y L
3 2 1 4 3 2 1 8 7 6 5 13 14 15 16
0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.5 0.5 0.75 0.75
Y/ G R /W R/B G /Y G /W G /B L L / R L/ Y L / W Br L/W B/R L 1
6 5 4 8 7 6 5 12 11 10 9 17 18 19 20 5
0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 B/W
G R W /L W /B W/R G/R G/B R/L
H6 H8 H12 H20 H22
TSHK0035
E75 E112
Terminal Terminal
Number Number
1 Boost pressure sensor GND 1 CMP shield
2 Boost pressure sensor Vout 2 CMP GND
3 Boost pressure sensor Vcc 3 CMP +
E76 E113
Terminal Terminal
Number Number
1 Engine oil pressure sensor GND 1 Common rail pressure sensor GND
2 Engine oil pressure sensor Vout 2 Common rail pressure sensor Vout
3 Engine oil pressure sensor Vcc 3 Common rail pressure sensor Vcc
E80 E161
Terminal Terminal
Number Number
1 EGR Vcc 1 SCV — Hi
2 EGR hall sensor W 2 SCV — Lo
3 EGR hall sensor V
E163
4 EGR hall sensor U
Terminal
5 EGR GND
Number
6 EGR motor W
1 Boost temperature sensor GND
7 EGR motor V
2 Boost temperature sensor +
8 EGR motor U
E164
E90
Terminal
Terminal Number
Number
1 ECT GND
2 ECT + H1
3 ECT meter Terminal
Number
E93 1 Glow
Terminal
Number H6
1 Fuel temperature sensor GND Terminal
Number
2 Fuel temperature sensor +
1 SCV − Lo
E98 2 SCV − Hi
Terminal 3 Fuel temperature sensor +
Number
4 ECT meter
1 CKP +
5 —
2 CKP GND
H8 Terminal
Terminal Number
Number 14 Common rail pressure sensor GND
1 EGR hall sensor U 15 Boost temperature sensor +
2 EGR hall sensor V 16 Boost pressure sensor Vout
3 EGR hall sensor W 17 Boost pressure sensor GND
4 — 18 —
5 EGR motor U 19 —
6 EGR motor V 20 —
7 EGR motor W
H22
8 —
Terminal
Number
H12
1 Glow
Terminal
Number
H94
1 —
Terminal
2 —
Number
1 —
2 OS — INJ1 signal/Injector #1
5 —
9 —
10 —
8 —
12 OS-INJ5 signal/Injector #2 H95
Terminal
H20 Number
Terminal 1 —
Number
1 CKP +
2 CKP GND
3 CKP shield
5 —
4 CMP +
5 CMP GND
6 CMP shield
8 —
7 ECT +
8 Boost pressure sensor Vcc
9 Engine oil pressure sensor Vcc
10 Engine oil pressure sensor Vout
11 Engine oil pressure sensor GND
12 Common rail pressure sensor Vcc
13 Common rail pressure sensor Vout
Cylinder head
H95
(Female connector on injector side)
In cylinder head
H94
(Female connector
on injector side)
H95
(Male connector on ECM side)
H94
(Male connector on ECM side)
TSWG0041
H94/H95 connector
Name
1. Engine harness-side connector
2. Cylinder head outside connector
3. Cylinder head inside connector
4. Injector harness-side connector
Connector list No. Connector Face
No. Connector Face
E-57
E-27
Machine harness side (female terminal)
#1 injector (Black)
(silver)
1 2 3
E-75
E-29 003-501
Engine harness side (male terminal)

#2 injector (Black)
(silver)
1 2 3
E-76
E-31 003-501

#3 injector (Black)
(silver)
E-80
E-33
#4 injector (Black)
(silver)
1 2
E-90 3
E-35 003-500
#5 injector (Light gray)
(silver)
E-93
E-37
#6 injector (Green)
(silver)
E-98
E-56
Machine harness side (female terminal) (Dark gray)
(Black)
No. Connector Face No. Connector Face
1 2 3 4 5 6 7 8
FL-150 9 10 11 12 13 14 15 16
E-112
016-500
Engine harness side (male terminal) Engine harness side (male terminal)
(Black)
1 2 3
FL-269
E-113 003-502

(Black)
H-1
000-009
E-114 (Silver)

(Black)
H-6

E-161 (Black)

(Light gray)
H-6

E-163

(Gray) H-8

(Black)
E-164
000-009
(Silver)
H-8

FB-124

(Black) H-12

(Black)
No. Connector Face No. Connector Face
H-12 H-94
Machine harness side (female terminal) Injector harness side (male terminal)
1 2 3 4
5 6 7 8
9 10 11 12
H-20
13 14 15 16 H-95
17 18 19 20
020-500
Machine harness side (male terminal) Engine harness side (male terminal)
(Gray)
4 3 2 1
8 7 6 5
12 11 10 9
H-20 16 15 14 13
20 19 18 17
020-501 H-95
Engine harness-side (female terminal)
(Light gray) Cylinder head outside (female terminal)
(Dark gray)
H-22
H-95
Engine harness-side (female terminal)
(Light gray) Cylinder head inside (female terminal)
(Dark gray)
H-22
H-95
Machine harness side (male terminal)

Injector harness side (male terminal)
H-94

(Dark gray)
H-94
Cylinder head outside (female terminal)

(Dark gray)
H-94
Cylinder head inside (female terminal)

(Dark gray)
List of Function Checks

List of function checks
Interview Inspection to comprehend the trouble symptom and diagnose properly based on a cus-
tomer’s complaint.
OBD system check Inspection to identify defective point of engine control system (inspection procedure)
Diagnosis lamp illumination cir- Inspection when diagnosis lamp does not come on when starter switch is turned ON.
cuit system check
Diagnosis lamp blinking circuit Inspection when diagnosis lamp does not blink (remains on) when diagnostic switch is
system check turned ON.
Scan tool power supply circuit Inspection when scan tool (Tech2) does not operate.
system check
Scan tool communication circuit Inspection when scan tool (Tech2) cannot communicate with ECM.
system check
Starting circuit system check Inspection when starter does not operate.
Starting system check Inspection when starter operates but engine does not start.
Fuel system check Inspection when relevant points to fuel system may be faulty (inspection procedure).
Intake system check Inspection when relevant points to intake system may be faulty (inspection procedure).
Exhaust system check Inspection when relevant points to exhaust system may be faulty (inspection procedure).
EGR control system check Inspection when relevant points to EGR may be faulty (inspection procedure).
QOS control system check Inspection when relevant points to QOS (glow) may be faulty (inspection procedure).
CAN communication check Inspection when fault relevant to machine control unit and CAN communication between
scan tool and ECM may exist.
Machine-side check Inspection when fault relevant to machine function (inspection procedure) may exist.
In the subsequent part of this manual, “scan tool” indicates scan tools including Tech2.
OBD system check
About OBD system check Note for OBD system check
OBD system check is systematic method to check the Important:
problems which caused by engine control system mal- • If there is no complaint for operationality,
function. It is the first procedure of all complaint diagno- never perform this diagnostic step unless oth-
sis for operationality. Use of this diagnostic step erwise instructed in other items.
properly enables to shorten the diagnosis period and to
• Before the diagnosis, check the service infor-
prevent unnecessary replacement of proper parts.
mation.
Test description • Never erase DTCs unless otherwise instructed
in the diagnostic step.
5. Communication disability with scan tool is caused by
• If fault is found in the engine starting system,
fault in the communication circuit between each ECU
refer to “Electrical system” in the service man-
and scan tool.
ual “Engine section”.
8. If DTC is detected, proceed to the relevant DTC
diagnosis by referring to 1E-284, “List of Diagnostic • Ensure the battery is fully charged.
Trouble Codes”. If more than one DTC is detected, • Make sure the battery cable is normal and
start with the one with smallest DTC number unless securely connected.
otherwise instructed in the diagnostic step. • Make sure the ground cable of ECM is con-
nected to the proper position securely.
Step Action Value YES NO

2. Check the diagnosis lamp (trouble display
1 monitor on the machine). —
Go to “Diagnosis
Does the diagnosis lamp (trouble display monitor lamp illumination cir-
on the machine) come on? Go to Step 2. cuit system check”.
1. Connect the diagnosis connector.
• If the machine is not equipped with diagno-
2 sis lamp, Go to Step 3. —
2. Check the diagnosis lamp. Go to “Diagnosis
lamp blinking circuit
Does the diagnosis lamp blink? Go to Step 3. system check”.
3 Is the scan tool (KW communication) available? — Go to Step 4. Go to Step 6.
1. Connect the scan tool.
4 3. Turn the power switch of the scan tool to “ON”. — Go to “Scan tool
power supply circuit
Does the scan tool powered “ON”? Go to Step 5. system check”.
Communicate with ECM using scan tool. Go to “Scan tool
5 — communication cir-
Does it communicate with ECM properly? Go to Step 6. cuit system check”.
Turn the key switch to “START”.
6 — Go to “Starting cir-
Does the starter operate? Go to Step 7. cuit system check”.
7 — Go to “Starting sys-
Does the engine start? Go to Step 8. tem check”.
Check if DTC is detected.
8 — Go to the relevant
Is DTC detected? DTC diagnosis. Go to Step 9.

1. Check for following troubles.
• Engine stall
• Engine hunting, rough idling
• Engine output lowering, blow up fault,
engine breathing
9 • Exhaust gas contains a lot of white smoke. —
• Exhaust gas contains a lot of black smoke.
• Idling rotation cannot be adjusted.
• Idling rotation cannot be reduced. Go to the relevant
trouble symptom
Is the trouble detected? diagnosis. Normal system
Diagnosis lamp illumination circuit system check
(15A)*
A A
Meter
Tachometer
Boost
Diagnosis Engine oil QOS indicator Charge
Machine trouble temperature O/H lamp
lamp pressure lamp lamp lamp
diagnosis monitor lamp
3 H-6
1 E-164
Machine
control unit O/H switch
CAN LOW CAN HIGH

Generator
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 8 E-57

Engine control
module (ECM)
Engine oil
Diagnosis pressure QOS indicator Boost temperature
Tachometer signal
CAN HIGH CAN LOW
TSHK0022
Description of circuit Following inspections are necessary to detect these

The power supply voltage is supplied to the diagnosis causes.
lamp via key switch, and the signal from ECM will turn • Improper connection of harness connector and
the lamp on. The ECM turns the diagnosis lamp on dur- ECM connector
ing lamp check with the key switch “ON” and when – Poor connection of terminal from connector
DTC is detected. Also when the diagnosis connector is – Unmatched terminals are fitted.
connected, it blinks the diagnosis lamp according to the
– Damage of connector lock
DTC detected. A monitor circuit is provided inside the
ECM to monitor the lamp operation. – Poor contact between terminal and wire
• Damaged harness
Diagnostic aid – Visually check the harness for damage.
If the intermittent trouble is suspected, followings may – Check the relevant items on the scan tool data
be the cause. display while moving the connector and the har-
• Improper connection of harness connector ness which are related to the sensor. The varia-
• Defective harness routing tion of the display indicates the faulty part.
• Worn harness cladding
• Wire disconnection inside harness cladding

1 2. Check the diagnosis lamp. —
Go to “Diagnostic
Does the diagnosis lamp come on? aid”. Go to Step 2.
Remove the diagnosis lamp to check its condition.
2 — Replace the diagno-
Is the trouble detected? sis lamp. Go to Step 3.
Check for open/short circuit between the diagnosis
lamp and ECM and power supply circuit using
3 DMM. —
Is the trouble detected? Repair the harness. Go to Step 4.

4 Is EMPS available? — Go to Step 5. Go to Step 6.
1. Check the version of ECM software.
Refer to 1E-88, “Flash Tool (EMPS)” in this
section for check and rewriting of ECM.
2. Rewrite the software if version upgraded is
necessary.
Note:
5 —
EGR valve position learning is required after
replacing or rewriting the ECM.
Refer to 1E-197, “Installation of ECM, Engine con-
trol module (ECM), Engine Control System” in this
section for learning of EGR. Check the repair,
and Go to “OBD
Is the procedure completed? system check”. —
Replace the ECM.
Note:
6 Refer to 1E-197, “Installation of ECM, Engine con- —
section for learning of EGR. Check the repair,
and Go to “OBD
Is the procedure completed? system check”. —
Diagnosis lamp blinking circuit system check
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150
DLC Machine
control unit
5 FL-150 4 FL-150
CAN HIGH CAN LOW
TSHK0023
Description of circuit Following inspections are necessary to detect these

The power supply voltage is supplied to the diagnosis causes.
lamp via key switch, and the signal from ECM will turn • Improper connection of harness connector and
the lamp on. The ECM turns the diagnosis lamp on dur- ECM connector
ing lamp check with the key switch “ON” and when – Poor connection of terminal from connector
DTC is detected. Also when the diagnosis connector is – Unmatched terminals are fitted.
connected, it blinks the diagnosis lamp according to the
DTC detected. A monitor circuit is provided inside the
ECM to monitor the lamp operation. – Poor contact between terminal and wire
• Damaged harness
Diagnostic aid – Visually check the harness for damage.
If the intermittent trouble is suspected, followings may – Check the relevant items on the scan tool data
be the cause. display while moving the connector and the har-

2. Connect the DMM between the diagnosis con-
nector (male-side) and the ground.
1 0V
Is the DMM indication more than the specified

value? Go to Step 2. Go to Step 3.
Check for installation condition of the ECM connec-
tor and coupling connector.
2 1. Check for play or looseness in the connection. —

2. If the trouble is detected, repair as required.
Is the trouble detected? Verify repair. Go to Step 3.

1. Check for followings in the circuit between
ECM and diagnosis connector using breaker
box or DMM.
Refer to 1E-255, “Breaker box inspection pro-
cedure, Diagnosis lamp blinking circuit system
check, List of Function Checks”.
Note:
If breaker box is not available, refer to 1E-256,
3 “On-board check procedure for sensors, Diagnosis —
lamp blinking circuit system check, List of Function
Checks”.
• Open circuit
• High resistance

1. Check for following in the circuit between diag-
nosis connector and ground.
• Open circuit
4 • High resistance —

Check the diagnosis lamp blinking condition again.
5 2. Connect the diagnosis connector. —
3. Check the diagnosis lamp.
Go to “Diagnostic
Does the diagnosis lamp blink? aid”. Go to Step 6.
necessary.
Note:
7 —
section for learning of EGR.
Is the procedure completed? Verify repair. Go to Step 8.


Replace the ECM.
Note:
Is the procedure completed? Verify repair. —
Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
3 Open circuit/ Resistance • Key switch “OFF” 52 – Diagnosis con- 100Ω or less 10 MΩ or
high resistance measurement nector terminal more
Short circuit to Resistance • Key switch “OFF” 52 – Ground 10 MΩ or 100Ω or less
ground measurement more
On-board check procedure for sensors
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
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.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the har-
ness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
Scan tool power supply circuit system check
TSWG0162
Name
1. Battery cable 2. Power socket cable (AC/DC adapter)
Description of circuit • Improper connection of harness connector and

ECM connector
The ECM and other ECUs communicate with the scan
tool via data link connector (DLC). Power supply volt- – Poor connection of terminal from connector
age for the scan tool is provided from the battery. – Unmatched terminals are fitted.
Caution:
Use a 12-V battery from the chassis ground side for – Poor contact between terminal and wire
the power supply to the scan tool. • Damaged harness
– Visually check the harness for damage.
Diagnostic aid – Check the relevant items on the scan tool data
If the intermittent trouble is suspected, followings may display while moving the connector and the har-
be the cause. ness which are related to the sensor. The varia-
• Improper connection of harness connector tion of the display indicates the faulty part.
• Defective harness routing
Test description
Important:
Before starting this diagnostic step, check if the
Following inspections are necessary to detect these
scan tool operates properly on other machine.
causes.

Check the voltage of battery on the machine using
1 DMM. 10V Charge or replace
Is the voltage more than specified value? Go to Step 2. the battery.
Check for poor contact in the scan tool-side cable.
2 —
Is the trouble detected? Go to Step 3. Go to Step 4.
Correct the connection of the scan tool.
3 —
Is the procedure completed? Go to Step 4. —
Check for open/short circuit in the cable between Request for repair
scan tool and battery. by referring to the
4 —
operation manual of
Is the trouble detected? the scan tool. Go to Step 5.

1. Connect the scan tool to the machine.
2. Turn the power switch of the scan tool to “ON”. Check the repair,
5 —
and Go to “OBD
Does the scan tool powered “ON”? system check”. Go to Step 1.
Scan tool communication circuit system check
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150
DLC Machine
control unit
5 FL-150 4 FL-150
CAN HIGH CAN LOW
TSHK0023
Description of circuit – Unmatched terminals are fitted.

The engine control module (ECM) performs KW com- – Damage of connector lock
munication with the scan tool via 16-pin data link con- – Poor contact between terminal and wire
nector (DLC). • Damaged harness
Diagnostic aid
– Check the relevant items on the scan tool data
causes.
• Improper connection of harness connector and
ECM connector
– Poor connection of terminal from connector

Perform the OBD system check.
1 — Go to “OBD system
Is the procedure completed? Go to Step 2. check”.
tor and coupling connector.


1. Check the DLC for following conditions.
• Poor connection of terminal from connector
3 • Poor contact between terminal and wire —

ECM and DLC using breaker box or DMM.
cedure, Scan tool communication circuit sys-
tem check, List of Function Checks”.
Note:
“On-board check procedure for sensors, Scan tool
4 communication circuit system check, List of Func- —
tion Checks”.
• Open circuit
• High resistance
• Short circuit to ground

5 3. Communicate with ECM using scan tool. —
Go to “Diagnostic
Does it communicate with ECM properly? aid”. Go to Step 6.
necessary.
Note:
7 —
Is the procedure completed? Go to Step 9. Go to Step 8.


Replace the ECM.
Note:

9 —
3. Communicate with ECM using scan tool.
Does it communicate with ECM properly? Verify repair. Go to Step 2.

Name
1. Breaker box
2. DMM

4 Open circuit/ Resistance • Key switch “OFF” 38 – DLC terminal No. 100Ω or less 10 MΩ or
high resistance measurement 7 more
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Starting circuit system check
Starter ECM control
(100A)*
Starter
B
C
Battery
B
Generator
(15A)*
(60A)*
Glow relay Sterter relay

Starter cut relay Main relay
(10A)*
1 H-22
5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START
Engine
control
Glow Glow relay control module
plug (ECM)
TSHK0024
Starter safety relay control
Starter
B
Battery B
Generator
(100A)* L
(15A)* (60A)*
B C
Safty relay
L S
Glow relay
A A
1 H-22
B Br C B ACC Br C
5 (ON) (ST) (ON) (ST)
B/W
OFF OFF
ON ON
START START
1 H-1
Key switch
10 E-57
Engine
control
module (ECM)
Glow relay control
Glow
plug
TSHK0026
Description of circuit – Unmatched terminals are fitted.

ECM turns the starter relay “ON” when the key switch is – Damage of connector lock
turned to “START” position. When the starter relay is – Poor contact between terminal and wire
“ON”, the starter operates to start the engine. • Damaged harness
Diagnostic aid
• Worn harness cladding Test description
• Wire disconnection inside harness cladding Numbers below indicate step numbers in the diagnostic
Following inspections are necessary to detect these chart.
causes. 2. If these DTCs are detected, engine may not start.
ECM connector
4. When the ECM does not recognize the “START”
position signal from the key switch, the starter cut relay
is set “OFF”. Therefore, the starter relay will not turn
“ON”.

Is the emergency stop switch equipped? Turn the switch to
1 — OFF, then Go to
Step 2. Go to Step 2.
2. Check the DTC.
2 — Go to the relevant
Is the DTC P0340, P0341, P0615, P1345 or P1625 diagnosis of DTC
detected? detected. Go to Step 3.
3 Is the scan tool available? — Go to Step 4. Go to Step 17.
1. Turn the key switch to “START”.
2. Check for “Starter switch (ST)” on the data dis-
4 play using scan tool. —
Is the “Starter switch (ST)” displayed “ON”? Go to Step 6. Go to Step 5.

1. Check for followings in the circuit between key
switch and ECM using breaker box or DMM.
cedure, Starting circuit system check, List of
Function Checks”.
Note:
5 “On-board check procedure for sensors, Starting —
circuit system check, List of Function Checks”.
• Open circuit
• High resistance

2. Remove the starter cut relay.
6 3. Check for continuity between the starter cut —
relay switch-side terminals.

Replace the starter cut relay.
7 —
2. Remove the starter relay.
3. Connect the battery to the starter relay coil-
8 side terminal. —
4. Check for continuity between the starter relay
switch-side terminals.

Replace the starter relay.
9 —
10 — Go to “Diagnostic
Does the starter operate? aid”. Go to Step 11.

1. Check the following circuits for open circuit or
high resistance.
• Between key switch and starter cut relay
• Between starter cut relay and starter relay
11 • Between starter relay and ground —
• Between starter relay and starter

1. Inspect by referring to “Electrical system” in
the service manual “Engine section”
12 2. If the trouble is detected, repair as required. —

necessary.
Note:
14 —

Replace the ECM.
Note:

Turn the key switch to “START”. Check the repair,
16 — and Go to “OBD
Does the starter operate? system check”. Go to Step 1.
1. Check for followings in the circuit between key
switch and ECM using breaker box or DMM.
cedure, Starting circuit system check, List of
Function Checks”.
Note:
17 “On-board check procedure for sensors, Starting —
circuit system check, List of Function Checks”.
• Open circuit
• High resistance


2. Remove the starter cut relay.
18 3. Check for continuity between the starter cut —
relay switch-side terminals.

Replace the starter cut relay.
19 —
2. Remove the starter relay.
3. Connect the battery to the starter relay coil-
20 side terminal. —
4. Check for continuity between the starter relay
switch-side terminals.

Name
1. Breaker box
2. DMM

5, 17 Open circuit/ Resistance • Key switch “OFF” 46 – Key switch 100Ω or less 10 MΩ or
high resistance measurement “START” terminal more
6, 18 Open circuit/ Resistance • Key switch “OFF” Starter cut relay 100Ω or less 10 MΩ or
high resistance measurement • Relay alone Switch-side terminal more
8, 20 Open circuit/ Resistance • Key switch “OFF” Starter relay 100Ω or less 10 MΩ or
high resistance measurement • Relay alone Switch-side terminal more
• Relay “ON”
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Starting system check
2 E-161
SCV
1 E-161
0.75 0.75
R/B R/W
1 H-6 2 H-6
97 E-56 89 E-56 105 E-56 113 E-56
Engine control
module(ECM)
B+
TSHK0027
About starting system check Diagnostic aid

Starting system check is systematic method to detect If there is relevant DTC to CKP sensor or CMP sensor,
the cause of that engine does not start. Followings are the engine will not start until memory clear is per-
the preconditions for performing this diagnosis. formed.
• Battery is fully charged, and battery cable is If the intermittent trouble is suspected, followings may
securely connected. be the cause.
• Engine speed at cranking is normal. • Improper connection of harness connector
• Sufficient amount of fuel is supplied. • Defective harness routing
• No air mixed in the fuel. • Worn harness cladding
• Air cleaner element and fuel filter is normal. • Wire disconnection inside harness cladding
• Correct fuel is used.
causes.
Important: • Improper connection of harness connector and
Start with the DTC diagnosis relevant to fuel sys- ECM connector
tem if there is any. – Poor connection of terminal from connector
– Unmatched terminals are fitted.
– Poor contact between terminal and wire 5. If the engine starts with the SCV connector discon-
nected, SCV system may be faulty. Also, if the engine
Test description does not start, the fuel system may be faulty.
6. Check the signal and operation of each sensor and
Numbers below indicate step numbers in the chart.
injector.
4. If the SCV-LOW circuit is shorted to ground, the SCV
drive current will not be more than 900mA.

2. Crank the engine for 15 seconds.
2 3. Check the DTC. — Go to the relevant
diagnosis of DTC
Is DTC detected? detected. Go to Step 3.
While cranking the engine, check for “SCV F/B” on
4 the data display using scan tool. 900mA
Is the “SCV F/B” more than the specified value? Go to Step 5. Go to Step 6.
1. Disconnect the SCV connector.
5 2. Crank the engine. —
Go to “Fuel system
Does the engine start? Go to DTC P0090. check”.
Repair the SCV-LOW circuit between the ECM and
6 the SCV. —
1. Check the relevant items to the following using
scan tool to see if the values are normal.
(Refer to “Tech2 data reference valve” for
specified valve.)
• Engine coolant temperature (ECT) sensor
• Common rail pressure sensor
7 • EGR position sensor —
• Injector
2. If the trouble is detected, replace the circuit or

sensor as required.

1. Check for following faults.
• Engine mechanical timing is off.
• Improper installation position of flywheel
8 • Excessive clogging in intake system —
• Excessive clogging in exhaust system
Is the trouble detected? Go to Step 9. —

1. Clear the DTC.
Refer to 1E-20, “How to clear DTC, Procedure
of Trouble Diagnosis” in this section for how to
clear DTCs.
9 2. Turn the key switch to “OFF” for more than 10 —
seconds.


Check the DTC. Go to the relevant Check the repair,
10 — diagnosis of DTC and Go to “OBD
Is DTC detected? detected. system check”.
1. Check the PCV-LOW circuit between the ECM
and the SCV.
11 2. If the trouble is detected, repair the circuit as —
required.

1. Check for following faults.
• Engine mechanical timing is off.
• Improper installation position of flywheel
12 • Excessive clogging in intake system —
• Excessive clogging in exhaust system
Is the trouble detected? Go to Step 9. —

Fuel system check
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
4. Pre-filter
About fuel system • Worn harness cladding

Fuel system consists of the fuel tank, fuel filter, supply • Wire disconnection inside harness cladding
pump, common rail, and injector each of which is con- Following inspections are necessary to detect these
nected by the fuel pipe. causes.
Diagnostic aid ECM connector
Followings are considered as the major possible cause – Poor connection of terminal from connector
of the fault in fuel system. – Unmatched terminals are fitted.
• Air mixed in the fuel system. – Damage of connector lock
• Clogged fuel filter – Poor contact between terminal and wire
• Damage, clogging, improper connection of fuel
pipe
• Fuel tank fault
• Supply pump fault
• Injector fault
• Pressure limiter fault
If the intermittent trouble is suspected, followings may
be the cause.
• Improper connection of harness connector

Check the fuel quality.
1. Drain fuel from the fuel tank.
2. Add proper fuel.
1 —
3. Bleed air from the fuel.
Does the engine start? Go to Step 6. Go to Step 2.

Check the fuel quantity.
2 — Supply fuel, and Go
Is sufficient amount of fuel supplied? Go to Step 3. to Step 3.
Check if there are additional filters or parts, other
than genuine fuel filter, pre-filter and electromag-
3 netic pump, in the machine’s fuel pipe. —
Are there any additional filters or parts? Go to Step 4. Go to Step 5.

1. Remove the additional filter and bleed air.
• If the fuel resistance is increased, the DTC
4 P1093 or P1094 may be detected. —
Does the engine start? Go to Step 6. Go to Step 5.

1. Check for excessive dirt or clogging in the
(main and pre-) fuel filters.
2. Check for excessive dirt or clogging in the
electromagnetic pump filter.
5 3. If the trouble is detected, clean or replace. —
4. If air is entered in the main filter, examine the
cause and repair.

1. Check for damage, clogging, or improper con-
nection in the fuel pipe.

1. Check for following troubles in the fuel tank.
• Foreign matter mixed in the fuel
• Disconnection or damage in fuel supply
pipe
• Crush or damage in tank
7 • Wrong assembly of fuel pipe —
• Clogging at filler neck
• Water mixed in fuel

Bleed air from the fuel.
Note:
8 For work procedure, refer to “Engine section” in the —
service manual.

Intake system check
About intake system The intake system consists of the air cleaner, intake
pipe, turbocharger, etc. Intake air is supplied to the
Note:
engine through the air cleaner and intake manifold.
If intake system parts are installed by the machine
manufacturer, refer to the machine’s manual.

Check for excessive dirt or clogging in the air
1 cleaner. —
Clean or replace the air cleaner.
2 —
1. Check for crush, breakage, or air leakage in
the intake pipe.
2. Make sure that the intake pipe is a genuine
part.
3 • Check for bend or improper piping that may —
cause increasing in intake air resistance.
3. Check the reed valve for breakage.

Repair or replace the intake pipe or reed valve.
4 —
Check the turbocharger.
• Check for abnormal rattling in the turbine shaft.
• Check for oil leakage.
5 Note: —
For work procedure, refer to “Engine section” in the
service manual.

Repair or replace the turbocharger.
Note:
service manual.

Repair the machine.
7 —
Reed valve check If the reed valve is broken, bypass of intake air deterio-
rates air-fuel ratio (A/F), resulting in output lowering.
Check the reed valve for deformation or breakage.
TSWG0168
Name
1. Reed valve
2. EGR valve
3. Exhaust side
4. Intake side
Exhaust system check

About exhaust system
The exhaust system consists of the exhaust pipe, tail
pipe, etc.

Check for crush, breakage, or exhaust leakage in
1 the exhaust pipe and tail pipe. —
Repair or replace the exhaust pipe or tail pipe.
2 —
Repair the machine.
3 —
EGR control system check
Engine control
module (ECM)
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR valve
TSHK0028
Description of circuit
The ECM operates the EGR valve based on engine
speed, engine coolant temperature, intake air tempera-
ture, fuel injection amount, and barometric pressure.
The EGR motor drives the EGR valve, and the EGR
position sensor detects the EGR valve opening angle.

2. Check the DTC. Go to the relevant
1 —
diagnosis of DTC

2. Warm-up the engine until the engine coolant
temperature is 70°C (158°F).
3 3. Check the value for “EGR position” using scan ±3%
tool.
Is “EGR position” within the specified value? Normal system Go to Step 4.

1. Perform “EGR control test” using scan tool.
2. Press the “Up” “Down” soft key.
4 ±3%
3. Check the value for “EGR position”.
Is “EGR position” within the specified value? Go to Step 6. Go to Step 5.

Replace the EGR valve.
After replacing the EGR valve or ECM, the EGR
valve position learning must be performed in the
following procedure. Failure to perform above pro-
cedure may result in detection of DTC for EGR.
5 —

1. Check for damage or gas leakage in the EGR
pipe.

temperature is 70°C (158°F).
7 ±3%
3. Check the value for “EGR position” using scan
tool.
Is “EGR position” within the specified value? Verify repair. Go to Step 8.

1. Remove the EGR valve.
2. Check the EGR valve for anchoring, clogging,
8 etc. —
Is the trouble detected? Go to Step 9. Normal system

After replacing the EGR valve or ECM, the EGR
valve position learning must be performed in the
following procedure. Failure to perform above pro-
cedure may result in detection of DTC for EGR.
9 —

1. Check for damage or gas leakage in the EGR
pipe.

2. Check the DTC. Go to the relevant
11 —
diagnosis of DTC
EGR valve check
TSWG0150
Push the EGR valve with finger to make sure it opens/

closes smoothly. Also, make sure that the valve closes
completely when the finger is released.
EGR hysteresis
ON
OFF
60
(140 F)
TSWG0206
QOS system check
(100A)*
Starter
B
C
Battery
B
Generator
(15A)*
(60A)*
Glow relay Sterter relay

Starter cut relay Main relay
(10A)*
1 H-22
5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START
Engine
control
Glow Glow relay control module
plug (ECM)
TSHK0024
(15A)*
A A
Meter
Tachometer
Boost
3 H-6
1 E-164
Machine
CAN LOW CAN HIGH

Generator
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 8 E-57

Engine control
module (ECM)
Engine oil
Tachometer signal
CAN HIGH CAN LOW
TSHK0022
Note: Test description

The QOS circuit is the same for both the starter ECM
control specifications and the safety relay specifica-
7. The QOS indicator lamp turns on when the key
tions.
switch is “ON” for lamp check, even if the QOS is not
operating.
Description of circuit 12. The QOS indicator lamp goes off within maximum
The QOS (Quick On Start) system consists of the ECM, 10 seconds.
glow relay, glow plug, and QOS indicator lamp. When
the key switch is turned ON with low engine coolant
temperatures, the ECM determines the glow time and
operates the glow relay and QOS indicator lamp. After
a certain time has elapsed, the ECM will turn the glow
relay and QOS indicator lamp to “OFF”.

Perform the OBD check.

2. Check the DTC.
2 —
Is relevant DTC to the engine coolant temperature Go to the relevant
sensor, QOS indicator lamp, or glow reply diagnosis of DTC
detected? detected. Go to Step 3.
Check the fuse.
Check for blown out fuse relevant to the QOS sys-
3 tem. — If the fault still
remains after repair,
Check for short circuit between the fuse, ECM,
glow plug, and QOS indicator lamp.
1. Disconnect the harness from the fuse, glow
relay, ECM, glow plug, and QOS indicator
4 lamp. 10 MΩ or more
2. Measure the resistance between each glow
relay terminal, each QOS indicator lamp termi-
nal, and the ground.
Is the resistance specified value? Go to Step 6. Go to Step 5.

Repair the short circuit between the fuse, ECM,
5 glow plug, and QOS indicator lamp. —
Is the procedure completed? — Go to Step 6.
1. Replace the fuse.
6 —
3. Make sure that the fuse is not blown.

7 3. Check the QOS indicator lamp. —
Does the QOS indicator lamp come on? Go to Step 12. Go to Step 8.
2. Remove the QOS indicator lamp.
8 3. Check the QOS indicator lamp for blow out. —

1. Replace the QOS indicator lamp.
9 —
3. Check the QOS indicator lamp.
1. Disconnect the ECM connector.
2. Measure the resistance between the QOS indi-
10 cator lamp terminal-to-ECM harness and the 10 MΩ or more
ground.

Repair the QOS indicator lamp terminal-to-ECM
11 harness. —

12 3. Check the QOS indicator lamp. —
Does the QOS indicator lamp go OFF within 10

seconds? Go to Step 14. Go to Step 13.
13 necessary. If rewriting is not necessary, go to —
step 3.
3. Replace the ECM.

1. Perform “Glow plug relay” test using scan tool.
When the scan tool is not available, remove
the relay and test it by itself.
14 2. Press the “ON” “OFF” soft key. —
Does the glow relay display (contact) “ON” and

“OFF”? Go to Step 15. Go to Step 13.
2. Remove all the glow plugs.
3. Measure the resistance between each glow 6Ω (Normal
15
plug terminal and the ground. temperature)

1. Turn the glow relay “ON” using the “Glow plug
relay” test of the scan tool.
the glow relay and short between the termi-
nals.
16 2. Measure the voltage between each cylinder 18V
glow plug harness terminal and the ground
using DMM.
Are the voltages at all the cylinders more than

specified value? Go to Step 17. Go to Step 18.
1. Turn the glow relay “OFF” using the “Glow plug
test” of the scan tool.
the glow relay.
using DMM.
Are the voltages at all the cylinders specified

value? Normal system Go to Step 19.
Repair the open circuit between the glow relay and
the glow plug, or the short circuit to the ground cir-
18 cuit. —

Repair the power supply circuit between the glow
relay and the glow plug, or the short circuit to the
19 ignition power supply circuit. —


Replace the glow plug.
20 —
1. Turn the glow relay “ON” using the “Glow plug
the glow relay and short between the termi-
nals.
using DMM.
Are the voltages at all the cylinders more than

1. Turn the glow relay “OFF” using the “Glow plug
the glow relay.
using DMM.
Are the voltages at all the cylinders specified

value? Verify repair. Go to Step 17.
List of Diagnostic Trouble Codes

List of diagnostic trouble codes for Hitachi Construction Machinery Co., Ltd.
On some machines, the diagnosis lamp comes on instead of trouble display monitor on the machine.
4HK1
Recovery
Flash DTC Item to be Preconditions when Judgment Behavior when Diagno-
DTC DTC set condition from
code description detected DTC is set Time trouble occurs sis lamp
failure
P0087 227 No pump Common rail 900 rpm or more Actual rail pres- Approx. 3 Intense engine ON *1
pressure feed pressure sure is 15 Mpa sec. vibration, rough
(fuel leakage) does not (2,176 psi) or idling, output lower-
increase to less. ing, blow up fault,
the required black smoke emit-
area. ted, and excessive
output are possible.
Back-up:
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0088 118 Common rail Common rail • Key switch input Rail pressure is Approx. 5 Intense engine ON *1
pressure fault pressure voltage is 18V or more than 185 sec. vibration, rough
(1st stage) abnormal more. MPa (26832 psi). idling, output lower-
increase • DTC P0088, ing, blow up fault,
P0192, P0193 or black smoke emit-
P1635 is not ted, and excessive
detected. output are possible.
• Actual rail pressure Back-up:
is 2 MPa (290 psi) or Limited injection
more, and 70 rpm or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
Common rail Common rail • Key switch input Common rail Approx. 5 Intense engine ON *1
pressure fault pressure voltage is 18V or pressure fault (1st sec. vibration, rough
(2nd stage) abnormal more. stage) is com- idling, output lower-
increase • DTC P0088, pleted, and rail ing, blow up fault,
P0192, P0193 or pressure is more black smoke emit-
P1635 is not than 190 MPa ted, and excessive
detected. (27557 psi). output are possible.
Target RP upper
limit (80 MPa
{11603 psi})
P0089 151 Common rail Common rail • Key switch input Actual rail pres- Approx. 5 Intense engine ON *1
pressure fault pressure voltage is 18V or sure is 40 MPa sec. vibration, rough
(Excessive abnormal more. (5802 psi) or idling, output lower-
pressure feed increase • DTC P0089, more higher than ing, blow up fault,
in pump) P0192, P0193 or target rail pres- black smoke emit-
P1635 is not sure. ted, and excessive
• Coolant tempera- Back-up:
ture is 60°C (140°F) Limited injection
or more, and 375 amount 3 (multi-
rpm or more. injection stopped)
• Duty to SCV is Target RP upper
40% or more, or limit (80 MPa
SCV target pres- {11603 psi})
sure feed is 90 mm3/
sec (0.0055cu⋅in/
sec) or less.
Recovery
failure
P0090 247 SCV drive Open/short • Main relay power When SCV drive Approx. 2 Engine stall and/or ON *2
system open circuit of supply voltage is current exceeds sec. engine blow up are
circuit, +B SCV/harness 18V or more. 2400 mA or drops possible depending
short or • DTC P1630 is not below 50 mA, or on the condition of
ground short detected. when the differ- open/short circuit.
• SCV drive duty is ence between tar- Black smoke emit-
between 10 — 90%. get and actual ted, excessive out-
current exceeds put
1000 mA or more. Back-up:
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0107 71 Barometric Open/short • Key switch input Barometric pres- Approx. 5 Due to back-up ON *2
pressure sen- circuit/deteri- voltage is 18V or sure sensor volt- sec. equivalent to 2000
sor fault (low oration of more. age is lower than m (6562 ft)
voltage fault) sensor or • DTC P1630 or 0.5 V. • Black smoke emit-
harness P1632 is not ted at high altitude
detected. • Output shortage at
low altitude
Back-up:
Barometric pres-
sure default set-
ting (80 kPa {11.6
psi})
EGR stopped
P0108 Barometric Short circuit • Key switch input Barometric pres- Approx. 5 Due to back-up ON *2
pressure sen- in sensor or voltage is 18V or sure sensor volt- sec. equivalent to 2000
sor fault (high harness more. age is more than m (6562 ft)
voltage fault) • DTC P1630 or 3.8 V. • Black smoke emit-
P1632 is not ted at high altitude
low altitude
Back-up:
Barometric pres-
sure default set-
ting (80 kPa {11.6
psi})
EGR stopped
P0112 22 Intake air Short circuit • Key switch input Intake air temper- Approx. 4 Not in particular ON *2
temperature in sensor or voltage is 18V or ature sensor volt- sec. Back-up:
sensor fault harness more. age is less than Intake air tempera-
(low voltage • DTC P1630 or 0.1 V. ture default setting
fault) P1632 is not (at starting: −10°C
detected. {14°F}, at running:
25°C {77°F})
EGR stopped
P0113 Intake air Open/short • Key switch input Intake air temper- Approx. 4 Not in particular ON *2
temperature circuit/deteri- voltage is 18V or ature sensor volt- sec. Back-up:
sensor fault oration of more. age is more than Intake air tempera-
(high voltage sensor or • DTC P1630 or 4.95 V. ture default setting
fault) harness P1632 is not (at starting: −10°C
• 3 minutes or more 25°C {77°F})
has elapsed after EGR stopped
starting engine.
Recovery
failure
P0117 23 Engine cool- Short circuit • Key switch input Engine coolant Approx. 4 At normal tempera- ON *2
ant tempera- in sensor or voltage is 18V or temperature sen- sec. ture: Black smoke
ture sensor harness more. sor voltage is less emission, greater
fault (low volt- • DTC P1630 or than 0.1 V. engine combustion
age fault) P1633 is not noise possible.
detected. During idling at low
atmospheric temper-
atures: Rough idling,
engine stall, white
smoke emission
possible.
Back-up:
Coolant tempera-
ture default setting
(at starting: −20°C
{−4°F}, at running:
80°C {176°F})
EGR stopped
P0118 Engine cool- Open/short • Key switch input Engine coolant Approx. 4 At normal tempera- ON *2
ant tempera- circuit/break- voltage is 18V or temperature sen- sec. ture: Black smoke
ture sensor age of sen- more. sor voltage is emission, greater
fault (high sor or • DTC P1630 or more than 4.85 V. engine combustion
voltage fault) harness P1633 is not noise possible.
• 3 minutes or more atmospheric temper-
has elapsed after atures: Rough idling,
starting engine. engine stall, white
smoke emission
possible.
Back-up:
Coolant tempera-
80°C {176°F})
EGR stopped
P0182 211 Fuel temper- Short circuit • Key switch input Combustion tem- Approx. 4 Not in particular ON *2
ature sensor in sensor or voltage is 18V or perature sensor sec. Back-up:
fault (low volt- harness more. voltage is less Fuel temperature
age fault) • DTC P1630 or than 0.1 V. default setting
P1633 is not (at starting: −20°C
detected. {−4°F}, at running:
70°C {158°F})
P0183 Fuel temper- Open/short • Key switch input Combustion tem- Approx. 4 Not in particular ON *2
ature sensor circuit/break- voltage is 18V or perature sensor sec. Back-up:
fault (high age of sen- more. voltage is more Fuel temperature
voltage fault) sor or • DTC P1630 or than 4.85 V. default setting
harness P1633 is not (at starting: −20°C
has elapsed after
starting engine.
Recovery
failure
P0192 245 Common rail Short circuit • Key switch input Common rail Nearly Engine stall possible ON *2
pressure sen- in sensor or voltage is 18V or pressure sensor simulta- Output lowering
sor fault (low harness more. voltage is less neous to Back-up:
voltage fault) • DTC P1630 or than 0.7 V. fault Rail pressure feed-
P1635 is not occur- back control
detected. rence stopped
Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Switches the con-
trol to SCV com-
pulsory drive.
80 MPa target
P0193 Common rail Open/short • Key switch input Common rail Nearly Engine stall possible ON *2
pressure sen- circuit/break- voltage is 18V or pressure sensor simulta- Output lowering
sor fault (high age of sen- more. voltage is more neous to Back-up:
voltage fault) sor or • DTC P1630 or than 4.5 V. fault Rail pressure feed-
harness P1635 is not occur- back control
Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Switches the con-
trol to SCV com-
pulsory drive.
80 MPa target
P0201 271 Open circuit Open/short • Main relay power No injector 1 Approx. Intensive engine ON *1
in injection circuit in elec- supply voltage is monitor input sig- 2.4 sec. vibration, rough
nozzle #1 trical wiring 18V or more. nal exists. idling, output lower-
drive system No. 1 cylinder • 70 rpm or more ing, blow up fault
injector • DTC P0611, Back-up:
P1261 or P0201 is Injection for cylin-
not detected. der #1 stopped,
EGR stopped
EGR stopped
EGR stopped
EGR stopped
P0219 543 Overrun Engine speed • Key switch input When engine Approx. 1 Output lowering ON *2
abnormally voltage is 18V or speed is more sec. Back-up:
high more. than 2500 rpm. Limited injection
amount 1
Limitation is lifted
if the speed
decreases
Recovery
failure
P0237 32 Boost pres- Open/short • Key switch input Boost pressure Approx. 3 Black smoke emit- ON *2
sure sensor circuit/break- voltage is 18V or sensor voltage is sec. ted
fault (low voltage of sen- more. less than 0.1V. Back-up:
age fault) sor or • DTC P1630 or Boost pressure
harness P1634 is not default setting (160
detected. kPa)
Boost pressure
correction/EGR
stopped
P0238 Boost pres- Short circuit • Key switch input Boost pressure Approx. 3 Black smoke emit- ON *2
sure sensor in sensor or voltage is 18V or sensor voltage is sec. ted
fault (high harness more. more than 4.9V. Back-up:
voltage fault) • DTC P1630 or Boost pressure
P1634 is not default setting (160
detected. kPa)
Boost pressure
correction/EGR
stopped
P0335 15 Crank sen- Open circuit • CMP sensor pulse Cam signal exists When • Output lowering, ON *1
sor fault (no in sensor/wir- is normal. but no crank sig- trouble white smoke emis-
signal) ing • DTC P0335, nal. occurs 14 sion, intense engine
P0336, P0340, out of 21 vibration possible
P0341 or P1345 is samples. • Engine stall possi-
not detected. ble (restart is possi-
• Engine is running. ble when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
P0336 Crank sen- Broken teeth/ • CMP sensor pulse Number of pulse When • Output lowering, ON *1
sor fault (sig- unnecessary is normal. for crank signal is trouble white smoke emis-
nal fault) signal mixed • DTC P0335, mismatched. occurs 14 sion, intense engine
(such as P0336, P0340, out of 21 vibration possible
short circuit P0341 or P1345 is samples. • Engine stall possi-
with other not detected. ble (restart is possi-
wiring) • Engine is running. ble when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
P0340 14 Cam sensor Open circuit • Key switch input Crank signal When • Behavior does not ON *1
fault (no sig- in sensor/wir- voltage is 18V or exists but no cam trouble change during
nal) ing more. signal. occurs 7 engine running.
• Crank pulse is nor- out of 8 • After engine stalls,
mal. samples. engine will not start.
• DTC P0335, Back-up:
P0336, P0340, Engine running
P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
• Engine is running. Unable to identify
cylinder (unable to
restart)
P0341 Cam sensor Broken teeth/ • Key switch input Number of pulse When • Behavior does not ON *1
fault (signal unnecessary voltage is 18V or for cam signal is trouble change during
fault) signal mixed more. mismatched. occurs 7 engine running.
(such as • Crank pulse is nor- out of 8 • After engine stalls,
short circuit mal. samples. engine will not start.
with other • DTC P0335, Back-up:
wiring) P0336, P0340, Engine running
cylinder (unable to
restart)
Recovery
failure
P0380 66 Glow relay Open/short • Key switch input No glow relay When Deterioration of ON *1
fault circuit/dam- power supply volt- monitor signal trouble startability
age of relay age is higher than exists against occurs 25 Back-up:
or harness 16 V but lower than glow relay drive out of 30 No back-up action
32 V. instruction. samples.
P0487 44 EGR position Open/short • Main relay input EGR position out- Approx. 3 Exhaust gas is ON *2
fault (Brush- circuit/break- voltage is 18 V or put signal is sec. affected.
less specifi- age of sen- more. abnormal. Back-up:
cation) sor or • DTC P1630 or Instruction to fully
harness P1635 is not close EGR valve
detected.
P0488 45 EGR valve Trouble/open • DTC P1630, Difference Approx. Exhaust gas is ON *1
control fault circuit or P1635, P0487 or between target 10 sec. affected.
valve P0488 is not valve lift and Back-up:
engage/stuck detected. actual position is Instruction to fully
in drive motor • Main relay voltage more than 20%. close EGR valve
side is between 20 and
32 V.
P0522 294 Engine oil Open/short • Key switch input Engine oil pres- Approx. 4 Operationality is not ON *2
pressure sen- circuit/break- voltage is 18V or sure sensor volt- sec. affected.
sor fault (low age of sen- more. age is less than Back-up:
voltage fault) sor or • DTC P1633 is not 0.098V. No back-up action
harness detected.
P0523 Engine oil Short circuit • Key switch input Engine oil pres- Approx. 4 Operationality is not ON *2
pressure sen- in sensor or voltage is 18V or sure sensor volt- sec. affected.
sor fault (high harness more. age is more than Back-up:
voltage fault) • DTC P1633 is not 4.85V. No back-up action
detected.
P0601 53 ROM fault ROM fault ROM is faulty. Engine stopped ON *2
— Reflash failure — Back-up:
Engine stopped
P0603 54 EEPROM EEPROM EEPROM is Operationality is not ON *2
fault fault faulty. affected.
— —
Back-up:
No back-up action
P0606 51 CPU fault CPU fault Sub-CPU detects Nearly Output lowering ON Diag-
main CPU fault in simulta- Back-up: nosed for
100 msec after neous to Limited injection 100msec
key switch ON. fault amount 2 (multi- only after
(SUB-CPU resets occur- injection stopped) KEY-ON.
CPU.) rence
—
Sub-CPU detects Nearly Unable to start ON Diag-
100 msec after neous to SUB-CPU stops 100msec
key switch ON. fault CPU. only after
(SUB-CPU resets occur- KEY-ON.
CPU.) rence
52 CPU monitor- Sub-CPU • 480 msec or more RUN-SUB pulse Nearly Output lowering ON *2
ing IC fault fault has elapsed after does not change simulta- Back-up:
key switch ON. for 20 msec or neous to Limited injection
• Key switch input more. fault amount 1
power supply volt- occur-
age is higher than rence
16 V.
Recovery
failure
P0611 34 Charge cir- ECU charge • Main relay power When charge cir- Approx. Intensive engine ON *2
cuit fault circuit 1 fault supply voltage is cuit bank 1 volt- 1.5 sec. vibration, rough
(bank 1) (internal 18V or more. age inside ECU is idling, output lower-
burnout, low. ing, blow up fault,
open circuit, engine stall are pos-
etc.) sible.
Back-up:
Common 1 stop
(#1, #4 cylinders
stopped), EGR
stopped
P0612 Charge cir- ECU charge When charge cir- Approx. Intensive engine ON *2
cuit fault circuit 2 fault cuit bank 2 volt- 1.5 sec. vibration, rough
(bank 2) (internal age inside ECU is idling, output lower-
etc.) sible.
Back-up:
Common 2 stop
(#2, #3 cylinders
stopped), EGR
stopped
P1093 227 No pump Fuel leakage • Key switch input Actual rail pres- Approx. 5 Intense engine ON *1
pressure feed (large voltage is 18V or sure is 50 MPa sec. vibration, rough
(fuel leakage) amount) more. (7252 psi) or idling, output lower-
• 1200 rpm or more more lower than ing, blow up fault,
• Duty to SCV is target rail pres- black smoke emit-
33% or less, or pressure. ted, engine stall, and
sure feed is excessive output are
28000mm3/sec possible.
(1.7cu⋅in/sec) or Back-up:
more. Limited injection
• DTC P0192, amount 3 (multi-
P0193, P1093, injection stopped)
P0091, P1291, Target RP upper
P1292 or P1635 is limit (80 MPa
not detected. {11603 psi})
P1095 225 Pressure lim- Pressure lim- • Key switch input Pressure limiter is Approx. 1 Output lowering, ON *1
iter open iter is voltage is 18V or opened. sec. hunting
opened. more. Back-up:
• DTC P1095, Limited injection
P0192, P0193, amount 1
P1630, or P1635 is
not detected.
• 50 rpm or more
P1112 295 Boost tem- Open/short • Key switch input Boost tempera- Approx. 4 Operationality is not ON *2
perature sen- circuit/break- voltage is 18V or ture sensor volt- sec. affected.
voltage fault) sor or • DTC P1634 is not 0.1 V. No back-up action
harness detected.
P1113 Boost tem- Short circuit • Key switch input Boost tempera- Approx. 4 Operationality is not ON *2
perature sen- in sensor or voltage is 18V or ture sensor volt- sec. affected.
voltage fault) • Coolant tempera- 4.941V. No back-up action
ture is 50°C (122°F)
or more.
• 3 (or 5) minutes
have passed after
engine starting
(depending on the
machine manufac-
turer)
• DTC P1634 is not
detected.
Recovery
failure
P1173 542 Overheat Overheat • Key switch input Coolant tempera- Approx. 5 Operationality is not Does *2
condition voltage is 18V or ture is more than sec. affected. not
more. 110°C (230°F). Back-up: come
• DTC P1630, No back-up action on.
P1633, P0117 or
P0118 is not
detected.
• During operation
P1261 158 Injection noz- Open/short • Main relay power No injector 1 and Approx. 3 Intensive engine ON *1
zle common circuit in supply voltage is 4 monitor input sec. vibration, rough
1 drive sys- injector com- 18V or more. signal exists. idling, output lower-
tem fault mon 1-side • 70 rpm or more ing, blow up fault
electrical wir- • None of the follow- Engine stall is possi-
ing, EDU out- ing DTC sets are ble.
put part fault detected; DTC Back-up:
P0611, P1261 and Common 1 stop
P0201; DTC P0611, (#1, #4 cylinders
P1261 and P0204. stopped), EGR
stopped
P1262 159 Injection noz- Open/short • Main relay power No injector 2 and Approx. 3 Intensive engine ON *1
zle common circuit in supply voltage is 3 monitor input sec. vibration, rough
2 drive sys- injector com- 18V or more. signal exists. idling, output lower-
P0202; DTC P0612, (#2, #3 cylinders
P1262 and P0203. stopped), EGR
stopped
Recovery
failure
P1271 24 Accelerator Difference in • Key switch input Difference in Approx. 3 1 system fault...No Does *1
sensor 1-2 opening voltage is 18V or opening angle sec. back-up not
comparison angle more. between acceler- 2 system come
fault between • DTC P1630, ator sensors 1 fault...Accelerator on.
accelerator P1631, P1271, and 2 is 45% or opening angle is
sensors 1-2 P1277, P1278, more. controlled to 0%.
is 45% or P1282 or P1283 is Back-up:
more. not detected. 1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1277 Accelerator Open/short • Key switch input Accelerator sen- Approx. 1 1 system fault...No Does *1
sensor 1 fault circuit/break- voltage is 18V or sor 1 voltage is sec. back-up not
(low voltage age of sen- more. lower than 0.2 V. 2 system come
fault) sor or • DTC P1630, fault...Accelerator on.
harness P1277 or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
(high voltage age of sen- more. more than 4.9 V. 2 system come
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
Recovery
failure
P1345 16 Cam sensor Camshaft • Key switch input Correct cam When • Behavior does not ON *1
out of phase gear/crank- voltage is 18V or pulse does not trouble change during
shaft gear more. exist in crank gap occurs 7 engine running.
installing • DTC P0335, position. out of 8 • After engine stalls,
angle is out P0336, P0340, samples. engine will not start.
of phase, or P0341, P1345, or Back-up:
damage in P1635 is not Engine running
gear. detected. based on crank
• CMP sensor pulse when it is normal
is normal. After engine stops:
• Crank pulse is nor- Unable to identify
mal. cylinder (unable to
restart)
P1625 416 Main relay Open/ground • Key switch input Main relay system Approx. 2 Engine does not ON *2
system fault short circuit in voltage is 18V or voltage is 1V or sec. start.
(Not enter) harness, more. less with main Back-up:
relay OFF • DTC P1630 is not relay coil output No back-up action
anchoring detected. ON.
• 3 seconds or more
has elapsed after
key switch ON.
• Main relay drive
indication ON
Harness +B • DTC P1625 or Relay does not Approx. 5 Vehicle power sup- ON *1
short, relay P0606 is not cut off despite of sec. ply cannot be shut
ON anchor- detected. main relay coil off.
ing output OFF indi- Back-up:
cation. No back-up action
P1630 36 A/D conver- A/D conver- A/D conversion Immedi- Output lowering, ON *2
sion fault sion fault failure ately Black smoke emit-
ted
Back-up:
Analog sensor
system default
— processing
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
Recovery
failure
P1631 55 Voltage fault Power sup- • DTC P1630 is not Key switch power Approx. Idling ON *2
in 5-V power ply wiring detected. supply voltage is 0.5 sec. Back-up:
supply 1 short to sen- • Key switch input 5.5V or more, or Same to accelera-
sor, or break- power supply volt- 4.5V or less. tor sensor fault
age in age is between 16
element/cir- and 32 V.
cuit for power
P1632 Voltage fault • DTC P1630 is not Key switch power Approx. Due to back-up ON *2
supply regu-
in 5-V power detected. supply voltage is 0.5 sec. equivalent to 2000
lation inside
supply 2 • Key switch input 5.5V or more, or m (6562 ft)
ECM.
power supply volt- 4.5V or less. • Black smoke emit-
age is between 16 ted at high altitude
and 32 V. • Output shortage at
low altitude
Back-up:
Same to baromet-
ric pressure and
intake air tempera-
ture sensor fault
P1633 Voltage fault • DTC P1630 is not Key switch power Approx. At normal tempera- ON *2
in 5-V power detected. supply voltage is 0.5 sec. ture: Black smoke
supply 3 • Key switch input 5.5V or more, or emission, greater
power supply volt- 4.5V or less. engine combustion
age is between 16 noise possible.
and 32 V. During idling at low
atmospheric temper-
engine stall, white
smoke emission
possible.
Back-up:
Same to coolant
temperature, fuel
temperature, and
oil pressure sen-
sor fault
P1634 Voltage fault • DTC P1630 is not Key switch power Approx. Black smoke emit- ON *2
in 5-V power detected. supply voltage is 0.5 sec. ted
supply 4 • Key switch input 5.5V or more, or Back-up:
power supply volt- 4.5V or less. Same to boost
age is between 16 pressure and
and 32 V. boost temperature
sensor fault
P1635 Voltage fault • DTC P1630 is not Key switch power Approx. Engine blow up, out- ON *2
in 5-V power detected. supply voltage is 0.5 sec. put lowering, black
supply 5 • Key switch input 5.5V or more, or smoke emission,
power supply volt- 4.5V or less. engine stall are pos-
age is between 16 sible.
and 32 V. Back-up:
Same to rail pres-
sure sensor fault
and EGR position
sensor fault
U2104 84 CAN Bus CAN commu- • Key switch input Bus-off is At 3 sec. Set to idle speed. ON *3
fault nication fault voltage is 12 V or detected. continu- Back-up:
more. ously Switch to the
accelerator sensor
input operation
U2106 85 CAN timeout CAN commu- • DTC U2104 is not CAN data recep- At 1 sec. Set to idle speed. ON *3
fault nication fault detected. tion does not continu- Back-up:
• Key switch input complete at a set ously Switches to the
voltage is 12 V or time. accelerator sensor
more. input operation.
About recovery from failure
1 2
There are three modes for recovery from failure.
To clear the trouble displayed on the monitor of the Key ON
machine, one more ignition cycle may be needed after switch
and
the following ignition cycle. Engine
OFF
run
*1
Even if the DTC has restored normally, the diagnosis
lamp and back-up mode are not restored in the ignition
cycle that the DTC is detected. After turning the key ON
Diag
switch OFF, DTC diagnosis is performed when the lamp
vehicle starts again. If it is judged as normal, everything OFF
will be recovered to normal from the next ignition cycle.
1 2 3
ON
Back-up
Key ON mode
switch
and OFF
Engine
run OFF
TSWG0166
Name
1. DTC is detected.
ON 2. Returned to normal.
Diag
lamp
OFF
*3
When the DTC has recovered to normal in the ignition
cycle that the DTC is detected, the back-up mode will
ON be recovered normally, but the diagnosis lamp does not
Back-up
mode go off.
OFF
1 2
TSWG0165
Key ON
Name switch
1. DTC is detected. and
Enigne
2. Repair and inspection run OFF
3. Returned to normal.
*2 ON
Diag
When the DTC has recovered to normal condition in lamp
the ignition cycle that the DTC is detected, the diagno- OFF
sis lamp and back up mode will also be recovered.
ON
Back-up
mode
OFF
TSWG0207
Name
1. DTC is detected.
6HK1
Recovery
failure
P0087 227 No pump Common rail 900 rpm or more Actual rail pres- Approx. 3 Intense engine ON *1
pressure feed pressure sure is 15 Mpa sec. vibration, rough
(fuel leakage) does not (2176 psi) or less. idling, output lower-
increase to ing, blow up fault,
the required black smoke emit-
area. ted, and excessive
output are possible.
Back-up:
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0088 118 Common rail Common rail • Key switch input Rail pressure is Approx. 5 Intense engine ON *1
pressure fault pressure voltage is 18V or more than 185 sec. vibration, rough
(1st stage) abnormal more. MPa (26832 psi). idling, output lower-
increase • DTC P0088, ing, blow up fault,
P0192, P0193 or black smoke emit-
P1635 is not ted, and excessive
Target RP upper
limit (80 MPa
{11603 psi})
Common rail Common rail • Key switch input Common rail Approx. 5 Intense engine ON *1
pressure fault pressure voltage is 18V or pressure fault (1st sec. vibration, rough
(2nd stage) abnormal more. stage) is com- idling, output lower-
increase • DTC P0088, pleted, and rail ing, blow up fault,
P0192, P0193 or pressure is more black smoke emit-
P1635 is not than 190 MPa ted, and excessive
detected. (27557 psi). output are possible.
Target RP upper
limit (80 MPa
{11603 psi})
P0089 151 Common rail Common rail • Key switch input Actual rail pres- Approx. 5 Intense engine ON *1
pressure fault pressure voltage is 18V or sure is 40 MPa sec. vibration, rough
(Excessive abnormal more. (5802 psi) or idling, output lower-
pressure feed increase • DTC P0089, more higher than ing, blow up fault,
in pump) P0192, P0193 or target rail pres- black smoke emit-
P1635 is not sure. ted, and excessive
• Coolant tempera- Back-up:
ture is 60°C (140°F) Limited injection
or more, and 375 amount 3 (multi-
rpm or more. injection stopped)
• Duty to SCV is Target RP upper
40% or more, or limit (80 MPa
SCV target pres- {11603 psi})
sure feed is 90 mm3/
sec (0.0055cu⋅in/
sec) or less.
Recovery
failure
P0090 247 SCV drive Open/short • Main relay power When SCV drive Approx. 2 Engine stall and/or ON *2
system open circuit of supply voltage is current exceeds sec. engine blow up are
circuit, +B SCV/harness 18V or more. 2400 mA or drops possible depending
short or • DTC P1630 is not below 50 mA, or on the condition of
ground short detected. when the differ- open/short circuit.
• SCV drive duty is ence between tar- Black smoke emit-
between 10 — 90%. get and actual ted, excessive out-
current exceeds put
1000 mA or more. Back-up:
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0107 71 Barometric Open/short • Key switch input Barometric pres- Approx. 5 Due to back-up ON *2
pressure sen- circuit/deteri- voltage is 18V or sure sensor volt- sec. equivalent to 2000
sor fault (low oration of more. age is lower than m (6562 ft)
voltage fault) sensor or • DTC P1630 or 0.5 V. • Black smoke emit-
harness P1632 is not ted at high altitude
low altitude
Back-up:
Barometric pres-
sure default set-
ting (80 kPa {11.6
psi})
EGR stopped
P0108 Barometric Short circuit • Key switch input Barometric pres- Approx. 5 Due to back-up ON *2
pressure sen- in sensor or voltage is 18V or sure sensor volt- sec. equivalent to 2000
sor fault (high harness more. age is more than m (6562 ft)
voltage fault) • DTC P1630 or 3.8 V. • Black smoke emit-
P1632 is not ted at high altitude
low altitude
Back-up:
Barometric pres-
sure default set-
ting (80 kPa {11.6
psi})
EGR stopped
P0112 22 Intake air Short circuit • Key switch input Intake air temper- Approx. 4 Not in particular ON *2
temperature in sensor or voltage is 18V or ature sensor volt- sec. Back-up:
sensor fault harness more. age is less than Intake air tempera-
(low voltage • DTC P1630 or 0.1 V. ture default setting
fault) P1632 is not (at starting: −10°C
25°C {77°F})
EGR stopped
P0113 Intake air Open/short • Key switch input Intake air temper- Approx. 4 Not in particular ON *2
temperature circuit/deteri- voltage is 18V or ature sensor volt- sec. Back-up:
sensor fault oration of more. age is more than Intake air tempera-
(high voltage sensor or • DTC P1630 or 4.95 V. ture default setting
fault) harness P1632 is not (at starting: −10°C
has elapsed after EGR stopped
starting engine.
Recovery
failure
P0117 23 Engine cool- Short circuit • Key switch input Engine coolant Approx. 4 At normal tempera- ON *2
ant tempera- in sensor or voltage is 18V or temperature sen- sec. ture: Black smoke
ture sensor harness more. sor voltage is less emission, greater
fault (low volt- • DTC P1630 or than 0.1 V. engine combustion
age fault) P1633 is not noise possible.
atmospheric temper-
engine stall, white
smoke emission
possible.
Back-up:
Coolant tempera-
80°C {176°F})
EGR stopped
P0118 Engine cool- Open/short • Key switch input Engine coolant Approx. 4 At normal tempera- ON *2
ant tempera- circuit/break- voltage is 18V or temperature sen- sec. ture: Black smoke
ture sensor age of sen- more. sor voltage is emission, greater
fault (high sor or • DTC P1630 or more than 4.85 V. engine combustion
voltage fault) harness P1633 is not noise possible.
• 3 minutes or more atmospheric temper-
has elapsed after atures: Rough idling,
starting engine. engine stall, white
smoke emission
possible.
Back-up:
Coolant tempera-
80°C {176°F})
EGR stopped
P0182 211 Fuel temper- Short circuit • Key switch input Combustion tem- Approx. 4 Not in particular ON *2
ature sensor in sensor or voltage is 18V or perature sensor sec. Back-up:
fault (low volt- harness more. voltage is less Fuel temperature
age fault) • DTC P1630 or than 0.1 V. default setting
P1633 is not (at starting: −20°C
70°C {158°F})
P0183 Fuel temper- Open/short • Key switch input Combustion tem- Approx. 4 Not in particular ON *2
ature sensor circuit/break- voltage is 18V or perature sensor sec. Back-up:
fault (high age of sen- more. voltage is more Fuel temperature
voltage fault) sor or • DTC P1630 or than 4.85 V. default setting
harness P1633 is not (at starting: −20°C
has elapsed after
starting engine.
Recovery
failure
P0192 245 Common rail Short circuit • Key switch input Common rail Nearly Engine stall possible ON *2
pressure sen- in sensor or voltage is 18V or pressure sensor simulta- Output lowering
sor fault (low harness more. voltage is less neous to Back-up:
voltage fault) • DTC P1630 or than 0.7 V. fault Rail pressure feed-
P1635 is not occur- back control
Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Switches the con-
trol to SCV com-
pulsory drive.
80 MPa target
P0193 Common rail Open/short • Key switch input Common rail Nearly Engine stall possible ON *2
pressure sen- circuit/break- voltage is 18V or pressure sensor simulta- Output lowering
sor fault (high age of sen- more. voltage is more neous to Back-up:
voltage fault) sor or • DTC P1630 or than 4.5 V. fault Rail pressure feed-
harness P1635 is not occur- back control
Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Switches the con-
trol to SCV com-
pulsory drive.
80 MPa target
P0201 271 Open circuit Open/short • Main relay power No injector 1 Approx. Intense engine ON *1
drive system No. 1 cylinder • 70 rpm or more ing, blow up fault,
injector • DTC P0611, output lowering
P1261 or P0201 is Back-up:
not detected. Injection for cylin-
der #1 stopped,
EGR stopped
EGR stopped
EGR stopped
EGR stopped
EGR stopped
Recovery
failure
EGR stopped
amount 1
if the speed
decreases
detected. kPa {21.8 psi})
Boost pressure
correction/EGR
stopped
detected. kPa {21.8 psi})
Boost pressure
correction/EGR
stopped
P0335 15 Crank sen- Open circuit • CMP sensor pulse Cam signal exists When • Output lowering, ON *1
sor fault (no in sensor/wir- is normal. but no crank sig- trouble white smoke emis-
signal) ing • DTC P0335, nal. occurs 14 sion, intense engine
P0336, P0340, out of 21 vibration possible
P0341 or P1345 is samples. • Engine stall possi-
not detected. ble (restart is possi-
• Engine is running. ble when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
P0336 Crank sen- Broken teeth/ • CMP sensor pulse Number of pulse When • Output lowering, ON *1
sor fault (sig- unnecessary is normal. for crank signal is trouble white smoke emis-
nal fault) signal mixed • DTC P0335, mismatched. occurs 14 sion, intense engine
(such as P0336, P0340, out of 21 vibration possible
short circuit P0341 or P1345 is samples. • Engine stall possi-
with other not detected. ble (restart is possi-
wiring) • Engine is running. ble when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
Recovery
failure
P0340 14 Cam sensor Open circuit • Key switch input Crank signal When • Behavior does not ON *1
fault (no sig- in sensor/wir- voltage is 18V or exists but no cam trouble change during
nal) ing more. signal. occurs 7 engine running.
• Crank pulse is nor- out of 8 • After engine stalls,
mal. samples. engine will not start.
• DTC P0335, Back-up:
P0336, P0340, Engine running
cylinder (unable to
restart)
P0341 Cam sensor Broken teeth/ • Key switch input Number of pulse When • Behavior does not ON *1
fault (signal unnecessary voltage is 18V or for cam signal is trouble change during
fault) signal mixed more. mismatched. occurs 7 engine running.
(such as • Crank pulse is nor- out of 8 • After engine stalls,
short circuit mal. samples. engine will not start.
with other • DTC P0335, Back-up:
wiring) P0336, P0340, Engine running
cylinder (unable to
restart)
P0380 66 Glow relay Open/short • Key switch input No glow relay When Deterioration of ON *1
fault circuit/dam- power supply volt- monitor signal trouble startability
age of relay age is higher than exists against occurs 25 Back-up:
or harness 16 V but lower than glow relay drive out of 30 No back-up action
32 V. instruction. samples.
P0487 44 EGR position Open/short • Main relay input EGR position out- Approx. 3 Exhaust gas is ON *2
fault (Brush- circuit/break- voltage is 18 V or put signal is sec. affected.
less specifi- age of sen- more. abnormal. Back-up:
cation) sor or • DTC P1630 or Instruction to fully
harness P1635 is not close EGR valve
detected.
P0488 45 EGR valve Trouble/open • DTC P1630, Difference Approx. Exhaust gas is ON *1
control fault circuit or P1635, P0487, between target 10 sec. affected.
valve P0488 or P1635 is valve lift and Back-up:
engage/stuck not detected. actual position is Instruction to fully
in drive motor • Main relay voltage more than 20%. close EGR valve
side is between 20 and
32 V.
P0522 294 Engine oil Open/short • Key switch input Engine oil pres- Approx. 4 Operationality is not ON *2
pressure sen- circuit/break- voltage is 18V or sure sensor volt- sec. affected.
harness detected.
P0523 294 Engine oil Short circuit • Key switch input Engine oil pres- Approx. 4 Operationality is not ON *2
pressure sen- in sensor or voltage is 18V or sure sensor volt- sec. affected.
voltage fault) • DTC P1633 is not 4.85 V. No back-up action
detected.
P0601 53 ROM fault ROM fault ROM is faulty. Engine stopped ON *2
— Reflash failure — Back-up:
Engine stopped
P0603 54 EEPROM EEPROM EEPROM is Operationality is not ON *2
fault fault faulty. affected.
— —
Back-up:
No back-up action
Recovery
failure
P0606 51 CPU fault CPU fault Sub-CPU detects Nearly Output lowering, ON Diag-
main CPU fault in simulta- hunting nosed for
100 msec after neous to Back-up: 100msec
key switch ON. fault Limited injection only after
(SUB-CPU resets occur- amount 2 (multi- KEY-ON.
CPU.) rence injection stopped)
—
Sub-CPU detects Nearly Unable to start ON Diag-
100 msec after neous to SUB-CPU stops 100msec
key switch ON. fault CPU. only after
(SUB-CPU resets occur- KEY-ON.
CPU.) rence
52 CPU monitor- Sub-CPU • 480 msec or more RUN-SUB pulse Nearly Output lowering ON *2
ing IC fault fault has elapsed after does not change simulta- Back-up:
key switch ON. for 20 msec or neous to Limited injection
• Key switch input more. fault amount 1
power supply volt- occur-
age is higher than rence
16 V.
P0611 34 Charge cir- ECU charge • Main relay power When charge cir- Approx. Intensive engine ON *2
cuit fault circuit 1 fault supply voltage is cuit bank 1 volt- 1.5 sec. vibration, rough
(bank 1) (internal 18V or more. age inside ECU is idling, output lower-
etc.) sible.
Back-up:
Common 1 stop
(#1, #2, #3 cylin-
ders stopped),
EGR stopped
P0612 34 Charge cir- ECU charge When charge cir- Approx. Intensive engine ON *2
cuit fault circuit 2 fault cuit bank 2 volt- 1.5 sec. vibration, rough
(bank 2) (internal age inside ECU is idling, output lower-
etc.) sible.
Back-up:
Common 2 stop
(#4, #5, #6 cylin-
ders stopped),
EGR stopped
P0650 77 Check engine Lamp fault • Key switch input No check engine Approx. Operationality is not Does *1
lamp fault voltage is 18V or lamp monitor sig- 1.5 sec. affected. not
more. nal exists. Back-up: come
• DTC P0650 is not No back-up action on.
detected.
P1093 227 No pump Fuel leakage • Key switch input Actual rail pres- Approx. 5 Intense engine ON *1
pressure feed (large voltage is 18V or sure is 50 MPa sec. vibration, rough
(fuel leakage) amount) more. (7252 psi) or idling, output lower-
• 1200 rpm or more more lower than ing, blow up fault,
• Duty to SCV is target rail pres- black smoke emit-
33% or less, or pressure. ted, engine stall, and
sure feed is excessive output are
28000mm3/sec possible.
(1.7cu⋅in/sec) or Back-up:
more. Limited injection
• DTC P0192, amount 3 (multi-
P0193, P1093, injection stopped)
P0091, P0092, Target RP upper
P1291, P1292 or limit (80 MPa
P1635 is not {11603 psi})
detected.
Recovery
failure
P1095 225 Pressure lim- Pressure lim- • Key switch input Pressure limiter is Approx. 1 Output lowering ON *1
iter open iter is voltage is 18V or opened. sec. Back-up:
opened. more. Limited injection
• DTC P1095, amount 1
P0192, P0193,
P1630, or P1635 is
not detected.
• 50 rpm or more
P1112 295 Boost tem- Open/short • Key switch input Boost tempera- Approx. 4 Operationality is not ON *2
perature sen- circuit/break- voltage is 18V or ture sensor volt- sec. affected.
harness detected.
P1113 Boost tem- Short circuit • Key switch input Boost tempera- Approx. 4 Operationality is not ON *2
perature sen- in sensor or voltage is 18V or ture sensor volt- sec. affected.
voltage fault) • Coolant tempera- 4.95V. No back-up action
ture 50°C (122°F) or
more, or 3 (or 5)
minutes have
passed after engine
starting.
• DTC P1634 is not
detected.
more. 110°C (230°F) Back-up: come
• DTC P1630, while engine is No back-up action on.
P1633, P0117 or operated.
P0118 is not
detected.
P1261 158 Injection noz- Open/short • Main relay power No injector 1, 2, 3 Approx. 3 Intensive engine ON *1
zle common circuit in supply voltage is monitor input sig- sec. vibration, rough
1 drive sys- injector com- 18V or more. nal exists. idling, output lower-
P0201; DTC P0611, (#1, #2, #3 cylin-
P1261 and P0202; ders stopped),
DTC P0611, P1261 EGR stopped
and P0203.
P1262 159 Injection noz- Open/short • Main relay power No injector 4, 5, 6 Approx. 3 Intensive engine ON *1
zle common circuit in supply voltage is monitor input sig- sec. vibration, rough
2 drive sys- injector com- 18V or more. nal exists. idling, output lower-
P0204; DTC P0612, (#4, #5, #6 cylin-
P1262 and P0205; ders stopped),
DTC P0612, P1262 EGR stopped
and P0206.
Recovery
failure
P1271 24 Accelerator Difference in • Key switch input Difference in Approx. 3 1 system fault...No Does *1
sensor 1-2 opening voltage is 18V or opening angle sec. back-up not
comparison angle more. between acceler- 2 system come
fault between • DTC P1630, ator sensors 1 fault...Accelerator on.
accelerator P1631, P1271, and 2 is 45% or opening angle is
sensors 1-2 P1277, P1278, more. controlled to 0%.
is 45% or P1282 or P1283 is Back-up:
more. not detected. 1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
Recovery
failure
P1345 16 Cam sensor Camshaft • Key switch input Correct cam When • Behavior does not ON *1
out of phase gear/crank- voltage is 18V or pulse does not trouble change during
shaft gear more. exist in crank gap occurs 7 engine running.
installing • DTC P0335, position. out of 8 • After engine stalls,
angle is out P0336, P0340, samples. engine will not start.
of phase, or P0341, P1345, or Back-up:
damage in P1635 is not Engine running
gear. detected. based on crank
• CMP sensor pulse when it is normal
is normal. After engine stops:
• Crank pulse is nor- Unable to identify
mal. cylinder (unable to
restart)
P1625 416 Main relay Open/ground • Key switch input Main relay system Approx. 2 Engine does not ON *2
system fault short circuit in voltage is 18V or voltage is 1V or sec. start.
(Not enter) harness, more. less with main Back-up:
relay OFF • DTC P1630 is not relay coil output No back-up action
anchoring detected. ON.
• 3 seconds or more
has elapsed after
key switch ON.
• Main relay drive
indication ON
Harness +B • DTC P1625 or Relay does not Approx. 5 Vehicle power sup- ON *1
short, relay P0606 is not cut off despite of sec. ply cannot be shut
ON anchor- detected. main relay coil off.
ing output OFF indi- Back-up:
cation. No back-up action
P1630 36 A/D conver- A/D conver- A/D conversion Immedi- Output lowering, ON *2
sion fault sion fault failure ately Black smoke emit-
ted
Back-up:
Analog sensor
system default
— processing
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
Recovery
failure
P1631 55 Voltage fault Power sup- • DTC P1630 is not Key switch power Approx. Idling ON *2
in 5-V power ply wiring detected. supply voltage is 0.5 sec. Back-up:
supply 1 short to sen- • Battery voltage is 5.5V or more, or Same to accelera-
sor, or break- between 16V and 4.5V or less. tor sensor fault
age in 32V.
element/cir-
P1632 Voltage fault • DTC P1630 is not Key switch power Approx. Due to back-up ON *2
cuit for power
in 5-V power detected. supply voltage is 0.5 sec. equivalent to 2000
supply regu-
supply 2 • Battery voltage is 5.5V or more, or m (6562 ft)
lation inside
between 16V and 4.5V or less. • Black smoke emit-
ECM.
32V. ted at high altitude
• Output shortage at
low altitude
Back-up:
Same to baromet-
ric pressure and
intake air tempera-
ture sensor fault
P1633 Voltage fault • DTC P1630 is not Key switch power Approx. At normal tempera- ON *2
in 5-V power detected. supply voltage is 0.5 sec. ture: Black smoke
supply 3 • Battery voltage is 5.5V or more, or emission, greater
between 16V and 4.5V or less. engine combustion
32V. noise possible.
During idling at low
atmospheric temper-
engine stall, white
smoke emission
possible.
Back-up:
Same to coolant
temperature, fuel
temperature, and
oil pressure sen-
sor fault
P1634 Voltage fault • DTC P1630 is not Key switch power Approx. Black smoke emit- ON *2
in 5-V power detected. supply voltage is 0.5 sec. ted
supply 4 • Battery voltage is 5.5V or more, or Back-up:
between 16V and 4.5V or less. Same to boost
32V. pressure and
boost temperature
sensor fault
P1635 Voltage fault • DTC P1630 is not Key switch power Approx. Engine blow up, out- ON *2
in 5-V power detected. supply voltage is 0.5 sec. put lowering, black
supply 5 • Battery voltage is 5.5V or more, or smoke emission,
between 16V and 4.5V or less. engine stall are pos-
32V. sible.
Back-up:
Same to rail pres-
sure sensor fault
and EGR position
sensor fault
more. ously Switches to the
accelerator sensor
input operation.
About recovery from failure
1 2
There are three modes for recovery from failure.
To clear the trouble displayed on the monitor of the Key ON
machine, one more ignition cycle may be needed after switch
and
the following ignition cycle. Engine
OFF
run
*1
Even if the DTC has restored normally, the diagnosis
lamp and back-up mode are not restored in the ignition
cycle that the DTC is detected. After turning the key ON
Diag
switch OFF, DTC diagnosis is performed when the lamp
vehicle starts again. If it is judged as normal, everything OFF
will be recovered to normal from the next ignition cycle.
1 2 3
ON
Back-up
Key ON mode
switch
and OFF
Engine
run OFF
TSWG0166
Name
1. DTC is detected.
ON 2. Returned to normal.
Diag
lamp
OFF
*3
When the DTC has recovered to normal in the ignition
cycle that the DTC is detected, the back-up mode will
ON be recovered normally, but the diagnosis lamp does not
Back-up
mode go off.
OFF
1 2
TSWG0165
Key ON
Name switch
1. DTC is detected. and
Enigne
2. Repair and inspection run OFF
*2 ON
Diag
When the DTC has recovered to normal condition in lamp
the ignition cycle that the DTC is detected, the diagno- OFF
sis lamp and back up mode will also be recovered.
ON
Back-up
mode
OFF
TSWG0207
Name
1. DTC is detected.
DTC: P0087 (Flash code 227) Common rail low pressure fault (No pressure feed in supply
pump)
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
4. Pre-filter
Engine control
module (ECM)
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR valve
TSHK0028
The engine control module (ECM) monitors the pres-
sure inside of common rail based on the signal from
common rail pressure sensor. If the pressure is low,
ECM controls the SCV of supply pump to increase the
pressure inside of common rail. If fuel supply to the
supply pump is insufficient or the supply pump is faulty,
the pressure inside of common rail cannot be
increased.
Main trouble symptom

• Intense engine vibration
• Rough idling
• Output lowering
• Black smoke emitted
• Excessive output is possible.
Fuel system filter Back-up mode
• Limited injection amount 3 (multi-injection stopped)
4 • Target RP upper limit (80 MPa {11603 psi})
3
Recovery from failure

Refer to 1E-284, “List of Diagnostic Trouble Codes”
and “About recovery from failure” in this section for
5
recovery from failure.
The conditions to clear the MIL/DTC

• The present trouble turns to history trouble when
2
the condition is out of the range from DTC set con-
dition (recovery from failure).
• The check engine lamp will go off after the code
turns to history trouble and the key switch is turned
“OFF” then “ON” again.
1
• Using the scan tool, or memory clear switch and
TSHK0039
diagnostic switch operation enables to clear DTCs.
Name
1. Fuel pump strainer Diagnostic aid
2. Pre-fuel Filter Followings are suspected as the cause.
3. Electromagnetic pump filter • Injector internal trouble
4. Main fuel filter
5. Gauze filter • Supply pump internal trouble
• Air in the fuel system
• Fuel system pipe fault (fuel leakage, clogging,
Filter clogging in the fuel system may establish the
crush, etc.)
DTC set condition. Check as required.
• Fuel filter fault (clogging)
Preconditions when DTC is set • Fuel tank fault (clogging)
900 rpm or more • Pressure limiter trouble (operation under specified
pressure, degradation of sealability)
DTC set condition • ECM trouble
Actual rail pressure is 15 MPa (2176 psi) or less for 3 • Common rail pressure sensor trouble
seconds or more.
Test description
:Desired rail pressure 11. If the “Common rail pressure sensor” displays more
:Actual rail pressure than the specified value when the common rail pres-
sure sensor connector is removed, the circuit beyond
the sensor is normal including ECM.
Absolute pressure
30MPa(4351psi)
Actual 1 P1093
t2 > 5sec
t1 > 3sec
15MPa Actual 2
(2176psi) P0087
TSHK0130
Action taken when DTC is set

Check engine lamp comes on.

Bleed air from the fuel system.
Note:
service manual.

Check the fuel system in the following procedure.
1. Check the high pressure pipe and low pres-
sure pipe for looseness in the connection (fuel
leakage), crush or clogging.
2. Check the fuel pipe, fuel filter, and inside of the
3 fuel tank for freeze or waxing. (at cold temper- —
ature)
3. Check the feed pipe inside the fuel tank for
clogging of foreign matter.
Is the fuel system normal? Go to Step 5. Go to Step 4.

Repair or replace the faulty part.
4 —
Check for rise of fuel level in the oil level gauge or
5 light oil odor. —
Check the connection of the fuel pipe in each injec-
tor, and replace the injector if oil leakage is con-
firmed.
6 Note: —
service manual.

Check the injector.
1. Clear the DTC.
clear DTCs.
3. Select the “Boost temperature sensor” from
8 the menu. —
4. Select the “Injection stop at each injector” in
the “Common rail system”.
5. Press the “OFF” soft key to stop the fuel injec-
tion in the cylinder one by one, and check the
change in engine sound.
Is there any cylinder of which engine vibration and

engine sound did not change when it is stopped? Go to Step 10. Go to Step 9.
Replace the injector in the cylinder of which engine
sound did not change when it is stopped.
Note:
service manual.


Check the common rail pressure.
2. Check for “Common rail pressure” on the data
display using scan tool. At engine
3. Start the engine and run it at idle. stopped: Differ-
ential pressure
4. Check for “Differential fuel rail pressure” on the
data display using scan tool. −30 MPa (−
10
4351 psi); At
5. Race it quickly for about 5 times. idling, racing:
6. Check for “Differential fuel rail pressure” on the ±5 MPa (±725
data display using scan tool. psi)
Is each value of “Fuel rail pressure” (at engine

stopped, idling and racing) around the specified
2. Disconnect the common rail pressure sensor
connector.
11 4.8V
4. Check for “Common rail pressure sensor” on
the data display using scan tool.
Is the “Common rail pressure sensor” more than

the specified value? Go to Step 14. Go to Step 12.
1. Check the signal circuit between common rail
pressure sensor and ECM for short circuit to
signal circuits of other sensors using breaker
12 box or DMM. —

necessary.
Note:
14 —

Replace the ECM.
Note:

Replace the common rail (common rail pressure
16 sensor). —

1. Clear the DTC.
clear DTCs.
the menu. ±5 MPa (±725
17
psi)
4. Select the “Rail pressure control” in the “Com-
mon rail system”.
5. Press the “Up” soft key to check the value of
“Differential fuel pressure”.
Is “Differential fuel rail pressure” within the speci-

fied value? Go to Step 19. Go to Step 18.
Replace the supply pump.
18 —
Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
clear DTCs.
seconds.
4. Test run with the “Preconditions when DTC is
set”.
5. Check the DTC.
Is DTC P0087 detected? Go to Step 3. Go to Step 20.

20 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
Use the injector checker to stop injection in the
injector, and check the change in engine sound.
21 —
Note:
service manual.

connector.
3. Measure the voltage between the common rail
23 4.8V
pressure sensor power supply terminal and the
ground.


24 box or DMM. —

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.
About common rail pressure sensor Characteristics of common rail pressure

sensor
(V)
4.2
3 2 1
1
0 200(29008)
TSWG0055 MPa(psi)
Name TSWG0201
1. Sensor ground
2. Sensor signal
3. Sensor power supply
Name
1. Breaker box
2. DMM

12, 24 Short circuit to Voltage mea- • Disconnect the 82 – Ground 0V 1V or more
other signal cir- surement sensor connector. 90 – Ground
cuit • Key switch “ON”
DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage)
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
4. Pre-filter
Engine control
module (ECM)
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR valve
TSHK0028
Description of circuit • Output lowering

The common rail pressure sensor detects the common • Engine blow up fault
rail internal pressure. The common rail pressure sensor • Black smoke emitted
is installed to the common rail. As the common rail • Excessive output possible
internal pressure changes depending on engine condi-
tion, output voltage of the common rail pressure sensor Preconditions when DTC is set
will change (if the common rail internal fuel pressure is
low, output voltage becomes low, if the pressure is • Key switch input voltage is 18V or more.
high, the output voltage becomes high as well). The • DTC P0088, P0192, P0193, or P1635 is not
engine control module (ECM) reads this output voltage detected.
change, converting it into common rail internal pres- • Actual rail pressure is 2 MPa (290 psi) or more,
sure, to utilize for control. Dedicated communication and 70 rpm or more.
circuits are used for the sensor power supply (5V), SIG,
and ground in the common rail pressure sensor, which DTC set condition
are connected to the ECM. Also, the sensor circuit is
shielded to avoid electrical noise etc. 1st step
• Rail pressure is more than 185 MPa (26832 psi)
Main trouble symptom for 5 seconds or more.
• Intense engine vibration • Common rail pressure sensor voltage is 3.9 V or
more.
• Rough idling
2nd step Recovery from failure
• 1st stage is completed, and rail pressure is more Refer to 1E-284, “List of Diagnostic Trouble Codes”
than 190 MPa (27557 psi) for 5 seconds or more. and “About recovery from failure” in this section for
• Common rail pressure sensor voltage is 4.0 V or recovery from failure.
more.
Note:
Pressure limiter opens at 200 MPa (29008 psi), and
DTC P1095 is detected in this case.
• The diagnosis lamp will go off after the code turns
to history trouble and the key switch is turned
Common rail

pressure
T>1sec=P1095
Diagnostic aid
200 MPa
(29008psi)
be the cause.
190 MPa T • Improper connection of harness connector
(27557psi)
185 MPa • Defective harness routing
(26832psi)
T
T>5sec=P0088 • Wire disconnection inside harness cladding
causes.
TSHK0043 ECM connector
• Trouble is displayed on the monitor of the – Damage of connector lock
machine or diagnosis lamp comes on.
– Poor contact between terminal and wire
• Damaged harness
Back-up mode – Check the relevant items on the scan tool data
• Limited injection amount 3 (multi-injection stopped) display while moving the connector and the har-
• Target RP upper limit (80 MPa {11603 psi}) ness which are related to the sensor. The varia-
tion of the display indicates the faulty part.

2. Check the DTC.
3. Are the fuel-related parts only just replaced?
Air bleeding may not be performed sufficiently
2 —
after replacing fuel-related parts. Bleed air
again. Check the DTC after bleeding air.
Is any of the P0088, P0192, P0193, or P1635 Go to the relevant

detected? DTC detected. Go to Step 3.

1. Turn the key switch to “OFF” for more than 30
seconds.
2. Start the engine. Differential
3. Check for “Differential fuel rail pressure” on the pressure ±5
4
MPa (±725 psi)
data display using scan tool.
(at idle)
Is “Differential fuel rail pressure” within the speci- Go to “Diagnostic
fied value? Go to Step 5. aid”.
1. Check the fuel return pipe between the supply
pump and the fuel tank for breakage, twist, etc.
2. Check for clogging or twisting in the vent hose
of the fuel tank.
5 —
3. Check for foreign matter in the fuel tank.

1. Replace the common rail (common rail pres-
sure sensor) since it seems that abnormal
value of the pressure sensor is detected.
Note:
service manual.
2. Check the DTC.

Note:
service manual.

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

Check if other DTC is detected.
About common rail pressure sensor
3 2 1
TSWG0055
Name
1. Sensor ground
2. Sensor signal
Characteristics of common rail pressure

sensor
(V)
4.2
0 200(29008)
MPa(psi)
TSWG0201
DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in
supply pump)
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
4. Pre-filter
Engine control
module (ECM)
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR valve
TSHK0028

The common rail pressure sensor detects the common • Engine blow up fault
rail internal pressure. The common rail pressure sensor • Black smoke emitted
is installed to the common rail. As the common rail • Excessive output possible
internal pressure changes depending on engine condi-
tion, output voltage of the common rail pressure sensor Preconditions when DTC is set
will change (if the common rail internal fuel pressure is
low, output voltage becomes low, if the pressure is • Key switch input voltage is 18V or more.
high, the output voltage becomes high as well). The • DTC P0089, P0192, P0193 or P1635 is not
engine control module (ECM) reads this output voltage detected.
change, converting it into common rail internal pres- • Coolant temperature is 60°C (140°F) or more, and
sure, to utilize for control. Dedicated communication 375 rpm or more.
circuits are used for the sensor power supply (5V), SIG, • Duty to SCV is 40% or less, or SCV target pres-
and ground in the common rail pressure sensor, which sure feed is 90 mm3/sec (0.0055 cu⋅in/sec) or less.
shielded to avoid electrical noise etc.
DTC set condition
Main trouble symptom • Actual rail pressure is 40 MPa (5802 psi) or more
higher than target rail pressure for 5 seconds or
more.
• Rough idling
Action taken when DTC is set Diagnostic aid
• Trouble is displayed on the monitor of the If the intermittent trouble is suspected, followings may
machine or diagnosis lamp comes on. be the cause.
Back-up mode • Worn harness cladding
• Limited injection amount 3 (multi-injection stopped)
• Target RP upper limit (80 MPa {11603 psi}) causes.
ECM connector
Refer to 1E-284, “List of Diagnostic Trouble Codes” – Poor connection of terminal from connector
recovery from failure. – Unmatched terminals are fitted.
The conditions to clear the MIL/DTC – Poor contact between terminal and wire
• The present trouble turns to history trouble when • Damaged harness
the condition is out of the range from DTC set con- – Visually check the harness for damage.
dition (recovery from failure). – Check the relevant items on the scan tool data
• The diagnosis lamp will go off after the code turns display while moving the connector and the har-
to history trouble and the key switch is turned ness which are related to the sensor. The varia-
“OFF” then “ON” again. tion of the display indicates the faulty part.

2. Check the DTC.
2 —
Is any of the P0089, P0192, P0193, or P1635 Go to the relevant
detected? DTC detected. Go to Step 3.
seconds.
2. Start the engine. Differential
4 3. Check for “Differential fuel rail pressure” on the pressure ±5
data display using scan tool. MPa (±725 psi)
Is “Differential fuel rail pressure” within the speci- Go to “Diagnostic
fied value? aid”. Go to Step 5.
2. Wait for 2 minutes before the common rail
internal pressure goes down.
3. Turn the key switch to “ON”. Do not start Differential
engine. pressure −30
5
MPa (−4351
psi)
Is “Differential fuel rail pressure” the specified


2. Disconnect the SCV connector.
3. Check the SCV harness connector terminal for
poor contact, intermittent trouble, etc.
6 4. Disconnect the ECM harness connector. —
5. Check the ECM harness connector terminal for

connector.
3. Check the common rail pressure sensor har-
ness connector terminal for poor contact, inter-
mittent trouble, etc.
7 —
4. Disconnect the ECM harness connector.
5. Check the ECM harness connector terminal for

sensor).
Note:
service manual.

Note:
service manual.

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

1. Visually check the harness between the ECM
and the common rail pressure sensor for dam-
age.
12 —

About common rail pressure sensor On-board check procedure for sensors
3 2 1
2 1
TSWG0055 TSWG0197
Name Name
1. Power supply 1. Coupling connector between engine — the
2. Signal machine
3. GND 2. Machine harness
3. Sensor connector
4. Engine harness
sensor 1. Disconnect the coupling connector, and check the
(V) the wiring of sensor connector.
4.2 3. Check the harness from coupling connector for
open circuit.
0 200(29008)
MPa(psi)
TSWG0201
DTC: P0090 (Flash code 247) SCV drive system open circuit, +B short or ground short
2 E-161
SCV
1 E-161
0.75 0.75
R/B R/W
1 H-6 2 H-6
97 E-56 89 E-56 105 E-56 113 E-56
Engine control
module(ECM)
B+
TSHK0027
Description of circuit • SCV drive duty is between 10% — 90%.

The suction control valve (SCV) controls the fuel feed
pressure amount to the common rail. Once the SCV DTC set condition
installed to the supply pump receives the signal (volt- • When the SCV drive current becomes above 2400
age), the SCV closes the valve and pressure-feeds fuel mA for 2 seconds or more.
from the supply pump to the common rail. The engine • When the SCV drive current becomes 50 mA or
control module (ECM) operates the SCV to adjust the less for 2 seconds or more.
common rail pressure.
• When the difference between target and actual
current becomes 1000 mA for 2 seconds or more.
• Engine stall and/or engine blow up are possible Action taken when DTC is set
depending on the condition of open/short circuit.
• Trouble is displayed on the monitor of the
• Black smoke emitted machine or diagnosis lamp comes on.
• Excessive output
Preconditions when DTC is set

• Main relay power supply voltage is 18V or more. Back-up mode
• DTC P0090 is not detected. • Limited injection amount 3 (multi-injection stopped)
• Target RP upper limit (80 MPa {11603 psi}) • Improper connection of harness connector
Recovery from failure • Worn harness cladding
Refer to 1E-284, “List of Diagnostic Trouble Codes” • Wire disconnection inside harness cladding
and “About recovery from failure” in this section for Following inspections are necessary to detect these
recovery from failure. causes.
ECM connector
• The present trouble turns to history trouble when – Poor connection of terminal from connector
• The diagnosis lamp will go off after the code turns – Damage of connector lock
to history trouble and the key switch is turned – Poor contact between terminal and wire
“OFF” then “ON” again. • Damaged harness
• Using the scan tool, or memory clear switch and – Visually check the harness for damage.
diagnostic switch operation enables to clear DTCs. – Check the relevant items on the scan tool data
display while moving the connector and the har-
Diagnostic aid ness which are related to the sensor. The varia-
If the intermittent trouble is suspected, followings may tion of the display indicates the faulty part.
be the cause.

3 3. Check for “SCV F/B” on the data display using 50mA
scan tool.
Is the “SCV F/B” the specified value or less? Go to Step 4. Go to Step 5.

SCV and ECM using breaker box or DMM.
cedure, DTC: P0090 (Flash code 247) SCV
drive system open circuit, +B short or ground
short, List of Diagnostic Trouble Codes”.
Note:
“On-board check procedure for sensors, DTC:
4 P0090 (Flash code 247) SCV drive system open —
circuit, +B short or ground short, List of Diagnostic
Trouble Codes”.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace as
required.


SCV and ECM using breaker box or DMM.
cedure, DTC: P0090 (Flash code 247) SCV
drive system open circuit, +B short or ground
short, List of Diagnostic Trouble Codes”.
Note:
P0090 (Flash code 247) SCV drive system open
5 circuit, +B short or ground short, List of Diagnostic —
Trouble Codes”.
• Short circuit between terminals
• Short circuit to power supply circuit or ignition
power supply circuit
• Short circuit to other signal circuit
required.

Check the SCV body.
Between termi-
nals: 7.9 Ω;
2. Remove the harness from the SCV. Each terminal
6
3. Measure the resistance between the SCV con- to SCV body:
nector terminals. ∞Ω (at 20°C
{68°F})
Replace the supply pump (SCV).
Note:
service manual.

2. Clear the DTC.
clear DTCs.
seconds.
4. Start the engine, and test run with the “Precon-
ditions when DTC is set”.
5. Check the DTC.
Go to “Diagnostic
Is DTC P0090 detected? Go to Step 9. aid”.

necessary.
Note:
10 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
5. Check the DTC.

About SCV
4HK1
TSHK0007
6HK1 Breaker box inspection procedure
TSHK0008
Name
1. SCV
Name
1. Breaker box
2. DMM
Name
1. SCV-HI
2. SCV-LO

4 Open circuit/ Resistance • Disconnect the 105 – SCV terminal 5Ω or less 10 MΩ or
high resistance measurement SCV connector. 113 – SCV terminal more
• Key switch “OFF” 89 – SCV terminal
97 – SCV terminal
Short circuit to Resistance • Disconnect the 105 – Ground 10 MΩ or 100Ω or less
ground measurement SCV connector. 113 – Ground more
• Key switch “OFF” 89 – Ground
97 – Ground

5 Short circuit Resistance • Disconnect the 105 – 89 10 MΩ or 100Ω or less
between termi- measurement SCV connector. 105 – 97 more
nals • Key switch “OFF” 113 – 89
113 – 97
Short circuit to Voltage mea- • Disconnect the 105 – Ground 0V 18V or more
power supply surement SCV connector. 113 – Ground
circuit • Key switch “ON” 89 – Ground
97 – Ground
other signal cir- surement SCV connector. 113 – Ground
cuit • Key switch “ON” 89 – Ground
97 – Ground
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0107 (Flash code 71) Barometric pressure sensor circuit input is low (open circuit
or ground short)
A A Engine control
module (ECM)
Accelerator Accelerator
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW

20 H-20 19 H-20 18 H-20

TSHK0029
Description of circuit • Output shortage at low altitude

The barometric pressure sensor detects the barometric
pressure. The barometric pressure sensor is installed Preconditions when DTC is set
to the machine. As the barometric pressure changes • Key switch input voltage is 18V or more.
depending on altitude and weather condition, output • DTC P1630 or P1632 is not detected.
voltage of the barometric pressure sensor will change
(if the barometric pressure is low, output voltage DTC set condition
becomes low, if the barometric pressure is high, the
output voltage becomes high as well). The engine con- • Barometric pressure sensor voltage is 0.5V or less
trol module (ECM) reads this output voltage change, for 5 seconds or more.
converting it into barometric pressure, to utilize for opti-
mizing the fuel injection control and for calculating the Action taken when DTC is set
relative boost pressure. • Trouble is displayed on the monitor of the
Due to back-up equivalent to 2000 m (6562 ft)
• Black smoke emitted at high altitude
Back-up mode Following inspections are necessary to detect these
causes.
• Barometric pressure default setting (80 kPa {11.6
psi}) • Improper connection of harness connector and
ECM connector
• EGR stopped
Recovery from failure – Unmatched terminals are fitted.
Refer to 1E-284, “List of Diagnostic Trouble Codes” – Damage of connector lock
and “About recovery from failure” in this section for – Poor contact between terminal and wire
recovery from failure. • Damaged harness
• The present trouble turns to history trouble when display while moving the connector and the har-
the condition is out of the range from DTC set con- ness which are related to the sensor. The varia-
dition (recovery from failure). tion of the display indicates the faulty part.
diagnostic switch operation enables to clear DTCs. Test description
Diagnostic aid
3. In the case of present trouble, the “Barometric pres-
If the intermittent trouble is suspected, followings may sure sensor” displays less than the specified value. If
be the cause. more than the specified value, identify the cause by
• Improper connection of harness connector referring to “Diagnostic aid”.
• Defective harness routing 5. If the “Barometric pressure sensor” displays more
than the specified value when terminals between the
barometric pressure sensor connector are shorted, the
• Wire disconnection inside harness cladding circuit beyond the sensor is normal including ECM.

Perform the OBD system check. Perform the “OBD
1 — system check” and
Check the value for barometric pressure sensor
using scan tool.
3 0.5V
3. Check the value for “Barometric pressure sen-
sor” using scan tool.
Is the “Barometric pressure sensor” less than the Go to “Diagnostic

specified value? Go to Step 4. aid”.
Check for installation condition of the barometric
pressure sensor, ECM and coupling connector.
1. Check for play or looseness in the connection.
4 2. If the trouble is detected, repair or replace as —
required.


2. Disconnect the barometric pressure sensor
connector.
3. Short between the barometric pressure sensor
connector power supply terminal and the sig-
5 nal terminal using jump cable. 4.8V
Is the “Barometric pressure sensor” more than the

1. Check for followings in the power supply circuit
between ECM and barometric pressure sensor
using breaker box or DMM.
cedure, DTC: P0107 (Flash code 71) Baromet-
ric pressure sensor circuit input is low (open
circuit or ground short), List of Diagnostic
Trouble Codes”.
Note:
6 “On-board check procedure for sensors, DTC: —
P0107 (Flash code 71) Barometric pressure sensor
circuit input is low (open circuit or ground short),
List of Diagnostic Trouble Codes”.
• Open circuit
• High resistance
required.

1. Check for followings in the signal circuit
Trouble Codes”.
Note:
7 P0107 (Flash code 71) Barometric pressure sensor —
• Short circuit to barometric pressure sensor
ground circuit
• Open circuit
• High resistance
required.

Replace the barometric pressure sensor.
8 —

necessary.
Note:
10 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

2. Check the display of barometric pressure. 127 kPa (18.4
14 psi) (error
Does the display of “Barometric pressure” show value) Go to “Diagnostic
error value? Go to Step 15. aid”.
(Check the barometric pressure sensor circuit for
open circuit or ground short.)
15 1. Check for disconnection, play or looseness in —

the connection.
required.


Trouble Codes”.
Note:
• Open circuit
• High resistance
required.

Trouble Codes”.
Note:
17 P0107 (Flash code 71) Barometric pressure sensor —
• Short circuit to barometric pressure sensor
ground circuit
• Open circuit
• High resistance
required.

About barometric pressure sensor
(V)
2.279198
1 2 3
1.009671
40(5.8) 120(17.4) kPa(psi)
TSWG0205
TSWG0058
Name
1. Power supply Perform the inspection in the following procedure if
2. GND there is such an instruction to use breaker box in the
3. Signal step. After inspection, return to the diagnostic step.
Characteristics of barometric pressure sensor

The output voltage of barometric pressure sensor
changes according to the barometric pressure.
The scan tool with CAN communication displays a fixed
value when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value
if the value of 40 kPa (5.8 psi) or 120 kPa (17.4 psi) is
not changed.
When error occurs, error value (127 kPa {18.4 psi}) is
displayed. The following illustration shows the correla-
tion between physical value and voltage displayed in
the scan tools with CAN communication.
Tech2 and scan tools with KW communication can dis-
play both physical value and voltage.
Name
1. Breaker box
2. DMM

6, 16 Open circuit/ Resistance • Disconnect the 61 – Sensor connector 100Ω or less 10 MΩ or
high resistance measurement sensor connector. power supply terminal more
• Key switch “OFF”
7, 17 Short circuit to Resistance • Disconnect the 71 – 60 10 MΩ or 100Ω or less
ground circuit/ measurement sensor connector. 71 – Ground more
ground • Key switch “OFF”
Open circuit/ Resistance • Disconnect the 71 – Sensor connector 100Ω or less 10 MΩ or
high resistance measurement sensor connector. signal terminal more
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
ness. If only step 1 is faulty, replace the sensor.
DTC: P0108 (Flash code 71) Barometric pressure sensor circuit input is high (+5V short)
A A Engine control
module (ECM)
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW

20 H-20 19 H-20 18 H-20

TSHK0029
Description of circuit Preconditions when DTC is set

The barometric pressure sensor detects the barometric • Key switch input voltage is 18V or more.
pressure. The barometric pressure sensor is installed • DTC P1630 or P1632 is not detected.
to the machine. As the barometric pressure changes
depending on altitude and weather condition, output DTC set condition
voltage of the barometric pressure sensor will change
(if the barometric pressure is low, output voltage • Barometric pressure sensor voltage becomes 3.8
becomes low, if the barometric pressure is high, the V or more for 5 seconds or more.
output voltage becomes high as well). The engine con-
trol module (ECM) reads this output voltage change, Action taken when DTC is set
converting it into barometric pressure, to utilize for opti- • Trouble is displayed on the monitor of the
mizing the fuel injection control and for calculating the machine or diagnosis lamp comes on.
relative boost pressure.

Due to back-up equivalent to 2000 m (6562 ft) Back-up mode
• Black smoke emitted at high altitude • Barometric pressure default setting (80 kPa {11.6
• Output shortage at low altitude psi})
• EGR stopped
Recovery from failure • Improper connection of harness connector and
ECM connector
and “About recovery from failure” in this section for – Poor connection of terminal from connector
• Using the scan tool, or memory clear switch and – Check the relevant items on the scan tool data
diagnostic switch operation enables to clear DTCs. display while moving the connector and the har-
ness which are related to the sensor. The varia-
Diagnostic aid
If the intermittent trouble is suspected, followings may Test description
be the cause.
• Improper connection of harness connector 3. In the case of present trouble, the “Barometric pres-
• Defective harness routing sure sensor” displays more than the specified value. If
• Worn harness cladding less than the specified value, identify the cause by
• Wire disconnection inside harness cladding referring to “Diagnostic aid”.
Following inspections are necessary to detect these 5. If the “Barometric pressure sensor” displays more
causes. than the specified value when the barometric pressure
sensor connector is removed, the circuit beyond the
sensor is normal including ECM.

Check the value for barometric pressure sensor
using scan tool.
3 3.8V
Is the “Barometric pressure sensor” more than the Go to “Diagnostic

4 —
required.

connector.
5 0V
Is the “Barometric pressure sensor” less than the


1. Check the signal circuit between ECM and
barometric pressure sensor for short circuit to
the power supply circuit or ignition power sup-
ply circuit using breaker box or DMM.
ric pressure sensor circuit input is high (+5V
short), List of Diagnostic Trouble Codes”.
Note:
circuit input is high (+5V short), List of Diagnostic
Trouble Codes”.
Important:
If the barometric pressure sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.

1. Check for followings in the ground circuit
Note:
Trouble Codes”.
• Open circuit
• High resistance
required.

Replace the barometric pressure sensor.
8 —
necessary.
Note:
10 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

2. Check the display of barometric pressure. 127 kPa (18.4
14 psi) (error
Does the display of “Barometric pressure” show value) Go to “Diagnostic
(Check the barometric pressure sensor circuit for
short to +5V line or battery power supply circuit.)
required.

barometric pressure sensor for short circuit to
Note:
Trouble Codes”.
Important:
If the barometric pressure sensor circuit is
may be broken.


Note:
Trouble Codes”.
• Open circuit
• High resistance
required.
About barometric pressure sensor Tech2 and scan tools with KW communication can dis-
(V)
2.279198
1 2 3
1.009671
40(5.8) 120(17.4) kPa(psi)

TSWG0058
TSWG0205
Name
1. Power supply
2. GND
3. Signal
Characteristics of barometric pressure sensor

The output voltage of barometric pressure sensor
changes according to the barometric pressure.
if the value of 40 kPa (5.8 psi) or 120 kPa (17.4 psi) is
not changed.
When error occurs, error value (127 kPa {18.4 psi}) is
displayed. The following illustration shows the correla-
tion between physical value and voltage displayed in
the scan tools with CAN communication.
Name
1. Breaker box
2. DMM

power supply surement sensor connector.
circuit • Key switch “ON”
high resistance measurement sensor connector. ground terminal more
On-board check procedure for sensors 1. Disconnect the coupling connector, and check the
3 2. Disconnect the connector from sensor, and short
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness
DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND
short, short circuit)
A A Engine control
module (ECM)
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW

20 H-20 19 H-20 18 H-20

TSHK0029

The intake air temperature (IAT) sensor is the ther- • Key switch input voltage is 18V or more.
mistor type and the value of resistance changes • DTC P1630 or P1632 is not detected.
according to the temperature. The resistance is low
when the intake air temperature is high, and is high DTC set condition
when the temperature is low. The ECM energizes 5 V
to the IAT sensor through the pull up resistance, and • IAT sensor voltage is 0.1V or less for 4 seconds or
calculate the intake air temperature from the change in more.
voltage, to utilize various control such as fuel injection
control. If the resistance is low (temperature is high), Action taken when DTC is set
the voltage becomes low; if the resistance is high (tem- • Trouble is displayed on the monitor of the
perature is low), the voltage becomes high. machine or diagnosis lamp comes on.

• White smoke emission possible when starting at
low temperatures Back-up mode
• Intake air temperature default setting (at starting: −
10°C {14°F}, at driving: 25°C {77°F})
• EGR stopped • Wire disconnection inside harness cladding
Recovery from failure causes.
Refer to 1E-284, “List of Diagnostic Trouble Codes” • Improper connection of harness connector and
and “About recovery from failure” in this section for ECM connector
recovery from failure. – Poor connection of terminal from connector
• The present trouble turns to history trouble when – Poor contact between terminal and wire
• Damaged harness
diagnostic switch operation enables to clear DTCs. – Check the relevant items on the scan tool data
Diagnostic aid ness which are related to the sensor. The varia-
• To make sure the correct performance of the IAT
sensor, check with various temperatures using the
Test description
reckoner table between temperature and resis-
tance. If the sensor is faulty, operationality may be Numbers below indicate step numbers in the chart.
affected. 3. In case of present trouble, the “Intake air tempera-
If the intermittent trouble is suspected, followings may ture sensor” displays less than the specified value. If
be the cause. more than the specified value, identify the cause by
referring to “Diagnostic aid”.
5. If the “Intake air temperature sensor” displays more
• Defective harness routing than the specified value when the IAT sensor connec-
• Worn harness cladding tor is removed, the circuit beyond the sensor is normal
including ECM.

Check the value for IAT sensor using scan tool.
3 3. Check the value for “Intake air temperature 0.1V
sensor” using scan tool.
Is the “Intake air temperature sensor” less than the Go to “Diagnostic

Check for installation condition of the IAT sensor,
ECM and coupling connector.
4 —
required.

2. Disconnect the IAT sensor connector.
Is the “Intake air temperature sensor” more than


between ECM and IAT sensor using breaker
box or DMM.
cedure, DTC: P0112 (Flash code 22) Intake air
temperature sensor fault (low voltage fault,
GND short, short circuit), List of Diagnostic
Trouble Codes”.
Note:
P0112 (Flash code 22) Intake air temperature sen-
sor fault (low voltage fault, GND short, short cir-
cuit), List of Diagnostic Trouble Codes”.
• Short circuit to IAT sensor ground circuit
required.

Replace the IAT sensor.
7 —
necessary.
Note:
9 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.


2. Check the display of intake air temperature. 214°C (419°F)
13
(error value)
Does the display of “Intake air temperature” show Go to “Diagnostic
ECM and coupling connector. (Check the IAT sen-
sor circuit for ground short.)
required.

box or DMM.
GND short, short circuit), List of Diagnostic
Trouble Codes”.
Note:
sor fault (low voltage fault, GND short, short cir-
• Short circuit to IAT sensor ground circuit
required.
About IAT sensor Name

1. Signal
2. GND
Characteristics of intake air temperature

sensor
The output voltage of IAT sensor changes according to
the intake air.
if the value of −40°C (−40°F) or 120°C (248°F) is not
changed.
When error occurs, error value (214°C {419°F}) is dis-
played.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
(V)
4.8691
0.1797
-40 120
(-40) (248) F
TSWG0180
1000
100
10
Resistance
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
Name
1. Breaker box
2. DMM

On-board check procedure for sensors 2. Disconnect the connector from sensor, and short
3 3. Check the harness from coupling connector for
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open
circuit or short to power supply circuit)
A A Engine control
module (ECM)
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW

20 H-20 19 H-20 18 H-20

TSHK0029

The intake air temperature (IAT) sensor is the ther- • Key switch input voltage is 18V or more.
mistor type and the value of resistance changes • DTC P1630 or P1632 is not detected.
according to the temperature. The resistance is low
• 3 minutes or more has elapsed after starting
when the intake air temperature is high, and is high
engine.
when the temperature is low. The ECM energizes 5 V
to the IAT sensor through the pull up resistance, and
DTC set condition
calculate the intake air temperature from the change in
voltage, to utilize various control such as fuel injection • IAT sensor voltage is 4.95V or more for 4 seconds
control. If the resistance is low (temperature is high), or more.
the voltage becomes low; if the resistance is high (tem-
perature is low), the voltage becomes high. Action taken when DTC is set
Main trouble symptom machine or diagnosis lamp comes on.
• White smoke emission possible when starting at
low temperatures
Back-up mode • Worn harness cladding
• Intake air temperature default setting (at starting: − • Wire disconnection inside harness cladding
10°C {14°F}, at driving: 25°C {77°F}) Following inspections are necessary to detect these
causes.
• EGR stopped
Recovery from failure ECM connector
and “About recovery from failure” in this section for – Unmatched terminals are fitted.
recovery from failure. – Damage of connector lock
• Damaged harness
• The present trouble turns to history trouble when – Visually check the harness for damage.
• Using the scan tool, or memory clear switch and ness which are related to the sensor. The varia-
diagnostic switch operation enables to clear DTCs. tion of the display indicates the faulty part.
Diagnostic aid Test description
• To make sure the correct performance of the IAT Numbers below indicate step numbers in the chart.
sensor, check with various temperatures using the 3. In case of present trouble, the “Intake air tempera-
reckoner table between temperature and resis- ture sensor” displays more than the specified value. In
tance. If the sensor is faulty, operationality may be this case, identify the cause by referring to “Diagnostic
affected. aid”.
If the intermittent trouble is suspected, followings may 5. If the “Intake air temperature sensor” displays less
be the cause. than the specified value when terminals between the
• Improper connection of harness connector IAT sensor connector are shorted, the circuit beyond
• Defective harness routing the sensor is normal including ECM.

Check the value for IAT sensor using scan tool.
Is the “Intake air temperature sensor” more than Go to “Diagnostic

the specified value? Go to Step 4. aid”.
required.


2. Disconnect the IAT sensor connector.
3. Short the IAT sensor connector signal terminal
to the ground terminal using jump cable.
5 4. Turn the key switch to “ON”. 0V
5. Check the value for “Intake air temperature
Is the “Intake air temperature sensor” less than the

1. Check the signal circuit between ECM and IAT
sensor for short circuit to the power supply cir-
cuit or ignition power supply circuit using
breaker box or DMM.
temperature sensor fault (high voltage fault,
open circuit or short to power supply circuit),
Note:
sor fault (high voltage fault, open circuit or short to
power supply circuit), List of Diagnostic Trouble
Codes”.
Important:
If the IAT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.

box or DMM.
Note:
Codes”.
• Open circuit
• High resistance
required.


box or DMM.
Note:
Codes”.
• Open circuit
• High resistance
required.

Replace the IAT sensor.
9 —
necessary.
Note:
11 —

Replace the ECM.
Note:


2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

2. Check the display of intake air temperature.
3. Display of intake air temperature is 214°C
214°C (419°F)
15 (419°F) due to back-up mode after fault judg-
ment. (error value)
Does the display of “Intake air temperature” show Go to “Diagnostic

required.

1. Check the signal circuit between ECM and IAT
breaker box or DMM.
Note:
Codes”.
Important:
If the IAT sensor circuit is shorted to the power


box or DMM.
Note:
Codes”.
• Open circuit
• High resistance
required.

box or DMM.
Note:
Codes”.
• Open circuit
• High resistance
required.

About IAT sensor The scan tool with CAN communication displays a fixed
changed.
(V)
4.8691
Name
1. Signal
2. GND
0.1797
Characteristics of intake air temperature
sensor -40 120
(-40) (248) F
The output voltage of IAT sensor changes according to TSWG0180
the intake air.
1000
100
10
Resistance
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
Name
1. Breaker box
2. DMM

On-board check procedure for sensors Name

3
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
2 1 ness. Check from step 1 again.
4 • If only step 1 is faulty, replace the sensor.
TSWG0197
DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault,
GND short, short circuit)

5V

HIGH LOW temperature sensor
108 E-56 107 E-56 106 E-56 19 E-57 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
3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
2 E-98 1 E-98
Engine
coolant
temperature
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
TSHK0030
Description of circuit Main trouble symptom

The engine coolant temperature (ECT) sensor detects • At normal temperature: Black smoke emission,
the engine coolant temperature. The ECT sensor is greater engine combustion noise possible.
installed near the thermostat housing. The ECT sensor • During idling at low atmospheric temperatures:
is the thermistor type and the value of resistance inside Rough idling, engine stall, white smoke emission
the sensor changes according to the temperature. If the possible.
temperature is high, the resistance becomes low; if the
temperature is low, the resistance becomes high. The Preconditions when DTC is set
engine control module (ECM) is connected to the ECT
sensor via signal circuit and ground circuit, and ener- • Key switch input voltage is 18V or more.
gizes +5 V power supply to the signal circuit. ECM rec- • DTC P1630 or P1633 is not detected.
ognizes the applied voltage, which varies with change
in the resistance of ECT sensor according to tempera- DTC set condition
ture (If the temperature is high, the voltage becomes • ECT sensor voltage is 0.1V or less for 4 seconds
low; if the temperature is low, the voltage becomes or more.
high), as an input signal.
Action taken when DTC is set If the intermittent trouble is suspected, followings may
be the cause.
machine or diagnosis lamp comes on. • Improper connection of harness connector
Back-up mode
• Coolant temperature default setting (at starting: − causes.
20°C {−4°F}, at running: 80°C {176°F}) • Improper connection of harness connector and
• EGR stopped ECM connector
recovery from failure. – Poor contact between terminal and wire
• Damaged harness
The conditions to clear the MIL/DTC – Visually check the harness for damage.
• The present trouble turns to history trouble when – Check the relevant items on the scan tool data
the condition is out of the range from DTC set con- display while moving the connector and the har-
dition (recovery from failure). ness which are related to the sensor. The varia-
• Using the scan tool, or memory clear switch and tion of the display indicates the faulty part.
Test description
Diagnostic aid Numbers below indicate step numbers in the chart.
• DTC may be set at a overheat condition. 3. In case of present trouble, the “Engine coolant tem-
perature sensor” displays more than the specified
• After starting the engine, the thermostat begins to
value. In this case, identify the cause by referring to
open when the engine coolant temperature rises
“Diagnostic aid”.
(4H: 85°C {185°F}, 6H: 82°C {180°F}), and the
5. If the “Engine coolant temperature sensor” displays
engine coolant temperature is stabilized.
more than the specified value when the ECT sensor
• To make sure the correct performance of the ECT connector is removed, the circuit beyond the sensor is
sensor, check with various temperatures using the normal including ECM.
tance. If the sensor is faulty, operationality may be
affected.

Check the value for ECT sensor using scan tool.
3 3. Check the value for “Engine coolant tempera- 0.1V
ture sensor” using scan tool.
Is the “Engine coolant temperature sensor” less Go to “Diagnostic

than the specified value? Go to Step 4. aid”.
Check for installation condition of the ECT sensor,
4 —
required.


2. Disconnect the ECT sensor connector.
Is the “Engine coolant temperature sensor” more

than the specified value? Go to Step 7. Go to Step 6.
between ECM and ECT sensor using breaker
box or DMM.
cedure, DTC: P0117 (Flash code 23) Engine
coolant temperature sensor fault (low voltage
fault, GND short, short circuit), List of Diagnos-
tic Trouble Codes”.
Note:
6 P0117 (Flash code 23) Engine coolant temperature —
sensor fault (low voltage fault, GND short, short cir-
• Short circuit to ECT sensor ground circuit
2. Measure the resistance of ECT sensor to
check that the value is within normal range.
required.

Replace the ECT sensor.
7 —
necessary.
Note:
9 —

Replace the ECM.
Note:


2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

2. Check the display of the engine coolant tem-
perature. Display of engine coolant tempera-
ture is 214°C (419°F) due to back-up mode 214°C (419°F)
13
after fault judgment. (error value)
Does the display of “Engine coolant temperature”

show error value? Go to Step 14. Go to Step 11.
required.

box or DMM.
coolant temperature sensor fault (low voltage
fault, GND short, short circuit), List of Diagnos-
Note:
15 P0117 (Flash code 23) Engine coolant temperature —
sensor fault (low voltage fault, GND short, short cir-
• Short circuit to ECT sensor ground circuit
2. Measure the resistance of ECT sensor to
check that the value is within normal range.
required.

About ECT sensor
2 1
1 2 3
TSWG0061
Name
1. Sensor ground (for engine control) Perform the inspection in the following procedure if
2. Sensor signal (for engine control) there is such an instruction to use breaker box in the
3. Sensor signal (for meter) step. After inspection, return to the diagnostic step.
Characteristics of ECT sensor

The output voltage of ECT sensor changes according
to the engine coolant temperature. The scan tool with
CAN communication displays a fixed value when the
value exceeds the threshold voltage. Therefore, judge
as it is more than the threshold value if the value of −
40°C (−40°F) or 120°C (248°F) is not changed.
played.
(V) Name
4.8691 1. Breaker box
2. DMM
0.1797
-40 120
(-40) (248) F
TSWG0180

2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0118 (Flash code 23) Engine coolant temperature sensor input is high (open circuit
or short to power supply)

5V

108 E-56 107 E-56 106 E-56 19 E-57 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
3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
2 E-98 1 E-98
Engine
coolant
temperature
pressure sensor
CKP sensor
A
Engine control
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
TSHK0030

The engine coolant temperature (ECT) sensor detects • At normal temperature: Black smoke emission,
the engine coolant temperature. The ECT sensor is greater engine combustion noise possible.
installed near the thermostat housing. The ECT sensor • During idling at low atmospheric temperatures:
is the thermistor type and the value of resistance inside Rough idling, engine stall, white smoke emission
the sensor changes according to the temperature. If the possible.
temperature is high, the resistance becomes low; if the
temperature is low, the resistance becomes high. The Preconditions when DTC is set
engine control module (ECM) is connected to the ECT
sensor via signal circuit and ground circuit, and ener- • Key switch input voltage is 18V or more.
gizes +5 V power supply to the signal circuit. ECM rec- • DTC P1630 or P1633 is not detected.
ognizes the applied voltage, which varies with change • 3 minutes or more has elapsed after starting
in the resistance of ECT sensor according to tempera- engine.
ture (If the temperature is high, the voltage becomes
low; if the temperature is low, the voltage becomes DTC set condition
high), as an input signal.
• ECT sensor voltage is 4.85V or more for 4 sec-
onds or more.
Action taken when DTC is set If the intermittent trouble is suspected, followings may
be the cause.
machine or diagnosis lamp comes on. • Improper connection of harness connector
Back-up mode
• Coolant temperature default setting (at starting: − causes.
20°C {−4°F}, at running: 80°C {176°F}) • Improper connection of harness connector and
• EGR stopped ECM connector
• Damaged harness
• Using the scan tool, or memory clear switch and tion of the display indicates the faulty part.
Test description
• After starting the engine, the thermostat begins to 3. In case of present trouble, the “Engine coolant tem-
open when the engine coolant temperature rises perature sensor” displays more than the specified
(4H: 85°C {185°F}, 6H: 82°C {180°F}), and the value. If less than the specified value, identify the
engine coolant temperature is stabilized. cause by referring to “Diagnostic aid”.
• To make sure the correct performance of the ECT
less than the specified value when terminals between
sensor, check with various temperatures using the
the ECT sensor connector are shorted, the circuit
beyond the sensor is normal including ECM.
tance. If the sensor is faulty, operationality may be
affected.

Check the value for ECT sensor using scan tool.
Is the “Engine coolant temperature sensor” more Go to “Diagnostic

than the specified value? Go to Step 4. aid”.
required.


3. Short the ECT sensor connector signal termi-
nal to the ground terminal using jump cable.
5. Check the value for “Engine coolant tempera-
Is the “Engine coolant temperature sensor” less

ECT sensor for short circuit to the power sup-
ply circuit or ignition power supply circuit using
breaker box or DMM.
coolant temperature sensor input is high (open
circuit or short to power supply), List of Diag-
nostic Trouble Codes”.
Note:
6 If breaker box is not available, refer to 1E-371, —
P0118 (Flash code 23) Engine coolant temperature
sensor input is high (open circuit or short to power
supply), List of Diagnostic Trouble Codes”.
Important:
If the ECT sensor circuit is shorted to the power

box or DMM.
Note:
• Open circuit
• High resistance
required.


box or DMM.
Note:
• Open circuit
• High resistance
required.

9 —
necessary.
Note:
11 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.


2. Check the display of the “Engine coolant tem-
perature”.
Display of engine coolant temperature is 214°C (419°F)
15 214°C (419°F) due to back-up mode after fault (error value)
judgment.
Does the display of “Engine coolant temperature” Go to “Diagnostic

show error value? Go to Step 16. aid”.
16 —
required.

ECT sensor for short circuit to the power sup-
ply circuit or ignition power supply circuit using
breaker box or DMM.
Note:
Important:
If the ECT sensor circuit is shorted to the power

box or DMM.
Note:
• Open circuit
• High resistance
required.


box or DMM.
Note:
• Open circuit
• High resistance
required.
About ECT sensor Tech2 and scan tools with KW communication can dis-
2 1
(V)
4.7441
1 2 3
0.2129
-40 120
(-40) (248) F
TSWG0061
TSWG0181
Name
1. Sensor ground (for engine control)
2. Sensor signal (for engine control)
3. Sensor signal (for meter)
Characteristics of ECT sensor

40°C (−40°F} or 120°C (248°F) is not changed.
played.
Name
Breaker box inspection procedure 1. Breaker box
Perform the inspection in the following procedure if 2. DMM

3
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
TSWG0197
DTC: P0182 (Flash code 211) Fuel temperature sensor fault (low voltage fault, GND short)

5V

108 E-56 107 E-56 106 E-56 19 E-57 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
3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
2 E-98 1 E-98
Engine
coolant
temperature
pressure sensor
CKP sensor
A
Engine control
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
TSHK0030

The fuel temperature (FT) sensor is the thermistor type • Key switch input voltage is 18V or more.
and the value of resistance changes according to the • DTC P1630 or P1633 is not detected.
temperature. The fuel temperature (FT) sensor is
installed near the fuel inlet duct in the supply pump. DTC set condition
The resistance is low when the fuel temperature is
high, and is high when the temperature is low. The • FT sensor voltage is 0.1V or less for 4 seconds or
ECM energizes 5 V to the FT sensor through the pull more.
up resistance, and calculates the fuel temperature from
the change in voltage, to utilize for supply control etc. If Action taken when DTC is set
the resistance is low (temperature is high), the voltage • Trouble is displayed on the monitor of the
becomes low; if the resistance is high (temperature is machine or diagnosis lamp comes on.
low), the voltage becomes high.

Operationality is affected. Back-up mode
• Fuel temperature default setting (at starting: −20°C
{−4°F}, at running: 70°C {158°F})
ECM connector
• Using the scan tool, or memory clear switch and – Check the relevant items on the scan tool data
diagnostic switch operation enables to clear DTCs. display while moving the connector and the har-
Diagnostic aid
• When the engine cold (before starting engine), Test description
check if the temperatures of the FT sensor and IAT
sensor are close. Numbers below indicate step numbers in the chart.
If the intermittent trouble is suspected, followings may 3. In case of present trouble, the “Fuel temperature
be the cause. sensor” displays more than the specified value. In this
case, identify the cause by referring to “Diagnostic aid”.
• Improper connection of harness connector 5. If the “Fuel temperature sensor” displays more than
• Defective harness routing the specified value when the FT sensor connector is
• Worn harness cladding removed, the circuit beyond the sensor is normal
• Wire disconnection inside harness cladding including ECM.
causes.

Check the value for FT sensor using scan tool.
3 3. Check the value for “Fuel temperature sensor” 0.1V
using scan tool.
Is the “Fuel temperature sensor” less than the Go to “Diagnostic

Check for installation condition of the FT sensor,
required.

2. Disconnect the FT sensor connector.
using scan tool.
Is the “Fuel temperature sensor” more than the


between ECM and FT sensor using breaker
box or DMM.
cedure, DTC: P0182 (Flash code 211) Fuel
GND short), List of Diagnostic Trouble Codes”.
Note:
P0182 (Flash code 211) Fuel temperature sensor
fault (low voltage fault, GND short), List of Diagnos-
• Short circuit to FT sensor ground circuit
required.

Replace the supply pump (FT sensor).
7 —
necessary.
Note:
9 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.


2. Check the display of “Fuel temperature”.
Display of fuel temperature is 214°C (419°F) 214°C (419°F)
13 due to back-up mode after fault judgment. (error value)
Does the display of “Fuel temperature” show error Go to “Diagnostic
value? Go to Step 14. aid”.
14 —
required.

box or DMM.
GND short), List of Diagnostic Trouble Codes”.
Note:
fault (low voltage fault, GND short), List of Diagnos-
• Short circuit to FT sensor ground circuit
required.
About FT sensor Name

1. GND
2. Signal
Characteristics of FT sensor
The output voltage of FT sensor changes according to
the fuel temperature. The scan tool with CAN commu-
nication displays a fixed value when the value exceeds
the threshold voltage. Therefore, judge as it is more
than the threshold value if the value of −30°C (−22°F)
or 120°C (248°F) is not changed.
played.
(V) there is such an instruction to use breaker box in the
4.5195
0.1973
-30 120
(-22) (248) F
TSWG0203
25
Name
1. Breaker box
20 2. DMM
15
10
-30 0 30 60 90 120
(-22) (32) (86) (140) (194) (248) F
TSWG0210

2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open
circuit or short to power supply circuit)

5V

108 E-56 107 E-56 106 E-56 19 E-57 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
3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
2 E-98 1 E-98
Engine
coolant
temperature
pressure sensor
CKP sensor
A
Engine control
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
TSHK0030

The fuel temperature (FT) sensor is the thermistor type • Key switch input voltage is 18V or more.
and the value of resistance changes according to the • DTC P1630 or P1633 is not detected.
temperature. The fuel temperature (FT) sensor is
• 3 minutes or more has elapsed after starting
installed near the fuel inlet duct in the supply pump.
engine.
The resistance is low when the fuel temperature is
high, and is high when the temperature is low. The
DTC set condition
ECM energizes 5 V to the FT sensor through the pull
up resistance, and calculates the fuel temperature from • FT sensor voltage is 4.85V or more for 4 seconds
the change in voltage, to utilize for supply control etc. If or more.
the resistance is low (temperature is high), the voltage
becomes low; if the resistance is high (temperature is Action taken when DTC is set
low), the voltage becomes high. • Trouble is displayed on the monitor of the
Not in particular
Back-up mode • Wire disconnection inside harness cladding
• Fuel temperature default setting (at starting: −20°C
causes.
{−4°F}, at running: 70°C {158°F})
• Damaged harness
• When the engine cold (before starting engine), Numbers below indicate step numbers in the chart.
check if the temperatures of the FT sensor and IAT 3. In case of present trouble, the “Fuel temperature
sensor are close. sensor” displays more than the specified value. In this
If the intermittent trouble is suspected, followings may case, identify the cause by referring to “Diagnostic aid”.
be the cause. 5. If the “Fuel temperature sensor” displays less than
• Improper connection of harness connector the specified value when terminals between the FT
• Defective harness routing sensor connector are shorted, the circuit beyond the
• Worn harness cladding sensor is normal including ECM.

Check the value for FT sensor using scan tool.
using scan tool.
Is the “Fuel temperature sensor” more than the Go to “Diagnostic

required.

2. Disconnect the FT sensor connector.
3. Short the FT sensor connector signal terminal
to the ground terminal using jump cable.
5. Check the value for “Fuel temperature sensor”
using scan tool.
Is the “Fuel temperature sensor” less than the


1. Check the signal circuit between ECM and FT
breaker box or DMM.
Note:
fault (high voltage fault, open circuit or short to
Codes”.
Important:
If the FT sensor circuit is shorted to the power

box or DMM.
Note:
Codes”.
• Open circuit
• High resistance
required.


box or DMM.
Note:
Codes”.
• Open circuit
• High resistance
required.

Replace the supply pump (FT sensor).
9 —
necessary.
Note:
11 —

Replace the ECM.
Note:


2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

2. Check the display of “Fuel temperature”.
Display of fuel temperature is 214°C (419°F) 214°C (419°F)
15 due to back-up mode after fault judgment. (error value)
Does the display of “Fuel temperature” show error Go to “Diagnostic
16 —
required.

1. Check the signal circuit between ECM and FT
breaker box or DMM.
Note:
17 —
Codes”.
Important:
If the FT sensor circuit is shorted to the power


box or DMM.
Note:
Codes”.
• Open circuit
• High resistance
required.

box or DMM.
Note:
Codes”.
• Open circuit
• High resistance
required.

About FT sensor
25
20
15
10
-30 0 30 60 90 120
(-22) (32) (86) (140) (194) (248) F
TSWG0210

Name
1. GND Perform the inspection in the following procedure if
2. Signal there is such an instruction to use breaker box in the
Characteristics of FT sensor
The output voltage of FT sensor changes according to
the fuel temperature. The scan tool with CAN commu-
nication displays a fixed value when the value exceeds
the threshold voltage.
changed.
(V)
4.5195 Name
1. Breaker box
2. DMM
0.1973
-30 120
(-22) (248) F
TSWG0203

2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short
circuit)
Engine control
module (ECM)
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR valve
TSHK0028

The common rail pressure sensor detects the common • Engine stall possible
rail internal pressure. The common rail pressure sensor • Output lowering
is installed to the common rail. As the common rail
internal pressure changes depending on engine condi- Preconditions when DTC is set
tion, output voltage of the common rail pressure sensor
will change (if the common rail internal fuel pressure is • Key switch input voltage is 18V or more.
low, output voltage becomes low, if the pressure is • DTC P1630 or P1635 is not detected.
high, the output voltage becomes high as well). The
engine control module (ECM) reads this output voltage DTC set condition
change, converting it into common rail internal pres- • Common rail pressure sensor voltage becomes
sure, to utilize for control. Dedicated communication 0.7V or less.
circuits are used for the sensor power supply (5V), SIG,
and ground in the common rail pressure sensor, which
Action taken when DTC is set • Improper connection of harness connector
• Trouble is displayed on the monitor of the • Defective harness routing
machine or diagnosis lamp comes on. • Worn harness cladding
causes.
Back-up mode
• Rail pressure feedback control stopped ECM connector
• Limited injection amount 2 (multi-injection stopped) – Poor connection of terminal from connector
• EGR stopped – Unmatched terminals are fitted.
• Switches the control to SCV compulsory drive – Damage of connector lock
• 80 MPa target – Poor contact between terminal and wire
• Damaged harness
Refer to 1E-284, “List of Diagnostic Trouble Codes” – Check the relevant items on the scan tool data
and “About recovery from failure” in this section for display while moving the connector and the har-
recovery from failure. ness which are related to the sensor. The varia-
• The present trouble turns to history trouble when Test description
the condition is out of the range from DTC set con- Numbers below indicate step numbers in the chart.
dition (recovery from failure). 3. In case of present trouble, the “Common rail pres-
• The diagnosis lamp will go off after the code turns sure sensor” displays more than the specified value. In
to history trouble and the key switch is turned this case, identify the cause by referring to “Diagnostic
“OFF” then “ON” again. aid”.
• Using the scan tool, or memory clear switch and 5. If the “Common rail pressure sensor” displays more
diagnostic switch operation enables to clear DTCs. than the specified value when the common rail pres-
Diagnostic aid the sensor is normal including ECM.
be the cause.

Check the value for common rail pressure sensor
using scan tool.
3 0.7 V (at idle)
3. Check the value for “Common rail pressure
Is the “Common rail pressure sensor” output volt- Go to “Diagnostic

age less than the specified value? Go to Step 4. aid”.
Check for installation condition of the common rail
4 —
required.


connector.
5 0V
Is the “Common rail pressure sensor” output volt-

age specified value? Go to Step 8. Go to Step 6.
between ECM and common rail pressure sen-
sor using breaker box or DMM.
cedure, DTC: P0192 (Flash code 245) Com-
mon rail pressure sensor fault (low voltage
fault, short circuit), List of Diagnostic Trouble
Codes”.
Note:
P0192 (Flash code 245) Common rail pressure
sensor fault (low voltage fault, short circuit), List of
Diagnostic Trouble Codes”.
• Open circuit
• High resistance
required.

mon rail pressure sensor fault (low voltage
fault, short circuit), List of Diagnostic Trouble
Codes”.
Note:
sensor fault (low voltage fault, short circuit), List of
• Short circuit to common rail pressure sen-
sor ground circuit
required.

sensor).
Note:
service manual.


necessary.
Note:
10 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

required.

connector.
15 0V
4. Connect the DMM between the common rail
pressure sensor signal terminal and the
ground.
Does the DMM indicate the specified value? Go to Step 8. Go to Step 6.

About common rail pressure sensor Breaker box inspection procedure
3 2 1
TSWG0055
Name
1. GND
2. Signal
3. Power supply Name
1. Breaker box
2. DMM
sensor
(V)
4.2
0 200(29008)
MPa(psi)
TSWG0201

6 Open circuit/ Resistance • Disconnect the 87 – Sensor connector 100Ω or less 10 MΩ or

7 Short circuit to Resistance • Disconnect the 82 – 101 10 MΩ or 100Ω or less
ground circuit/ measurement sensor connector. 90 – 101 more
ground • Key switch “OFF” 82 – Ground
90 – Ground
• Key switch “OFF” 90 – Sensor connector
signal terminal
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault)
Engine control
module (ECM)
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR valve
TSHK0028

The common rail pressure sensor detects the common
rail internal pressure. The common rail pressure sensor Preconditions when DTC is set
is installed to the common rail. As the common rail • Key switch input voltage is 18V or more.
internal pressure changes depending on engine condi- • DTC P1630 or P1635 is not detected.
tion, output voltage of the common rail pressure sensor
will change (if the common rail internal fuel pressure is DTC set condition
low, output voltage becomes low, if the pressure is
high, the output voltage becomes high as well). The • Common rail pressure sensor voltage becomes
engine control module (ECM) reads this output voltage 4.5V or more.
change, converting it into common rail internal pres-
sure, to utilize for control. Dedicated communication Action taken when DTC is set
circuits are used for the sensor power supply (5V), SIG, • Trouble is displayed on the monitor of the
and ground in the common rail pressure sensor, which machine or diagnosis lamp comes on.
Main trouble symptom Back-up mode

• Engine stall possible • Rail pressure feedback control stopped
• Limited injection amount 2 (multi-injection stopped) • Wire disconnection inside harness cladding
• EGR stopped Following inspections are necessary to detect these
causes.
• Switches the control to SCV compulsory drive
• 80 MPa target
ECM connector
Recovery from failure – Poor connection of terminal from connector
and “About recovery from failure” in this section for – Damage of connector lock
• Damaged harness
• The diagnosis lamp will go off after the code turns tion of the display indicates the faulty part.
“OFF” then “ON” again. Test description
• Using the scan tool, or memory clear switch and Numbers below indicate step numbers in the chart.
diagnostic switch operation enables to clear DTCs. 3. In case of present trouble, the “Common rail pres-
sure sensor” displays more than the specified value. In
Diagnostic aid this case, identify the cause by referring to “Diagnostic
If the intermittent trouble is suspected, followings may aid”.
be the cause. 5. If the “Common rail pressure sensor” displays less
• Improper connection of harness connector than the specified value when terminals between the
common rail pressure sensor connector are shorted,
• Defective harness routing the circuit beyond the sensor is normal including ECM.

Check the value for common rail pressure sensor
using scan tool.
3 4.5V
Is the “Common rail pressure sensor” more than Go to “Diagnostic

the specified value? Go to Step 4. aid”.
4 —
required.


connector.
3. Short the common rail pressure sensor con-
nector power supply terminal and the signal
5 terminal using jump cable. 4.8V
Is the “Common rail pressure sensor” less than the

common rail pressure sensor for short circuit
to the power supply circuit or ignition power
supply circuit using breaker box or DMM.
mon rail pressure sensor fault (high voltage
fault), List of Diagnostic Trouble Codes”.
Note:
sensor fault (high voltage fault), List of Diagnostic
Trouble Codes”.
Important:
If the common rail pressure sensor circuit is
may be broken.

Note:
Trouble Codes”.
• Open circuit
• High resistance
required.


Note:
Trouble Codes”.
• Open circuit
• High resistance
required.

sensor).
Note:
service manual.

necessary.
Note:
11 —

Replace the ECM.
Note:


2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

15 —
required.

connector.
16 4. Connect the DMM between the common rail 4.8V
pressure sensor power supply terminal and the
signal terminal.
Is the DMM indication less than the specified


sensor
(V)
4.2
3 2 1
1
0 200(29008)
TSWG0055 MPa(psi)
Name TSWG0201
1. GND
2. Signal
3. Power supply
Name
1. Breaker box
2. DMM

6 Short circuit to Voltage mea- • Disconnect the 82 – Ground 0V 18V or more
power supply surement sensor connector. 90 – Ground
• Key switch “OFF” 90 – Sensor connector
signal terminal
8 Open circuit/ Resistance • Disconnect the 101 – Sensor connec- 100Ω or less 10 MΩ or
high resistance measurement sensor connector. tor ground terminal more

3
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
TSWG0197
DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system
4HK1
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

3 3
3 E-35 3 E-37 E-27 E-31
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56
Cylinder No. 3 Cylinder No. 2 Cylinder No. 1 Cylinder No. 4

B+ B+

TSHK0031
6HK1

2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

No. 5 No. 6 No. 4 No. 2 No. 1 No. 3

B+ B+

TSWG0076
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and ener-
gizes the pressurized voltage (more than 100 V) to the
injector. For injector operation, the voltage applied to
the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
Cylinder No. and injection order Fuel injection is performed to each cylinder in the order
of 1 — 5 — 3 — 6 — 2 — 4.
4HK1
• Rough idling
6
• Output lowering
1
• Engine blow up fault
2 Preconditions when DTC is set

• Main relay power supply voltage is 18V or more.
5 3 • 70 rpm or more
• DTC P0611, P1261, or P0201 is not detected.
4
DTC set condition
• Open/short circuit is detected in No. 1 cylinder
injector drive circuit.
TSHK0032
• No. 1 cylinder injector monitor input signal does
not exist for 2.4 seconds or more.
Name
1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3 • Trouble is displayed on the monitor of the
4. Cylinder No. 4 machine or diagnosis lamp comes on.
5. Cylinder block
6. Engine front
Back-up mode
Fuel injection order is 1 — 3 — 4 — 2.
• Injection for cylinder #1 stopped, EGR stopped
6HK1
8 Refer to 1E-284, “List of Diagnostic Trouble Codes”
1
2
3
4
7 • The diagnosis lamp will go off after the code turns
5 “OFF” then “ON” again.
6
Diagnostic aid
TSWG0157
Name be the cause.
1. Cylinder No. 1
2. Cylinder No. 2 • Improper connection of harness connector
3. Cylinder No. 3 • Defective harness routing
4. Cylinder No. 4 • Worn harness cladding
5. Cylinder No. 5 • Wire disconnection inside harness cladding
6. Cylinder No. 6 Following inspections are necessary to detect these
7. Cylinder block causes.
8. Engine front
• Improper connection of harness connector and • Damaged harness
ECM connector – Visually check the harness for damage.
– Poor connection of terminal from connector – Check the relevant items on the scan tool data
– Unmatched terminals are fitted. display while moving the connector and the har-
– Damage of connector lock ness which are related to the sensor. The varia-

Check the DTC.
seconds.
2 2. Start the engine. —
3. Check the DTC.
Go to “Diagnostic
Is DTC detected? Go to Step 3. aid”.
2. Remove the coupling connector (H-94) from
the cylinder head cover case.
0.45±0.1Ω
3 3. Measure the resistance between the coupling
(20°C {68°F})
connector terminals (power supply terminal —
No. 1 cylinder injector drive signal terminal).
Is the resistance less than the specified value? Go to Step 4. Go to Step 5.

ECM and coupling connector (H-94) using
breaker box or DMM.
cedure, DTC: P0201 (Flash code 271) Open
circuit in injection nozzle #1 drive system, List
of Diagnostic Trouble Codes”.
Note:
P0201 (Flash code 271) Open circuit in injection
nozzle #1 drive system, List of Diagnostic Trouble
Codes”.
• Open circuit
• High resistance

Check for installation condition of the injector termi-
nal nut.
1. Remove the cylinder head cover.
5 2. Check the injector terminal nut for looseness —
etc.

Check for installation condition of the coupling con-
nector.



1. Check for following in the circuit between injec-
tor terminal and coupling connector.
• Open circuit
required.
Is there any trouble in the circuit? Go to Step 13. Go to Step 9.

tor.
8 2. Remove the ECM. —


1. Replace the No. 1 cylinder injector.
Note:
service manual.

necessary.
Note:
11 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.



Name
1. Breaker box
2. DMM

4 Open circuit/ Resistance • Remove the cou- 119 – Coupling con- 100Ω or less 10 MΩ or
high resistance measurement pling connector. nector terminal (H-94) more
• Key switch “OFF” (4H: No. 5, 6H: No. 2)

3
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
TSWG0197
4HK1
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

3 3
3 E-35 3 E-37 E-27 E-31
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

B+ B+

TSHK0031
6HK1

2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

No. 5 No. 6 No. 4 No. 2 No. 1 No. 3

B+ B+

TSWG0076
of 1 — 5 — 3 — 6 — 2 — 4.
4HK1
• Rough idling
6
• Output lowering
1

• DTC P0612, P1262 or P0202 is not detected
4 (4HK1).
(6HK1).
DTC set condition

TSHK0032
Name
1. Cylinder No. 1
2. Cylinder No. 2 • No. 2 cylinder injector monitor input signal does
3. Cylinder No. 3 not exist for 2.4 seconds or more.
4. Cylinder No. 4
5. Cylinder block Action taken when DTC is set
6. Engine front • Trouble is displayed on the monitor of the
6HK1
Back-up mode
8
1

3

4
7 • The present trouble turns to history trouble when
5 dition (recovery from failure).
6
TSWG0157
Name
1. Cylinder No. 1 Diagnostic aid
2. Cylinder No. 2
3. Cylinder No. 3 If the intermittent trouble is suspected, followings may
4. Cylinder No. 4 be the cause.
7. Cylinder block • Worn harness cladding
8. Engine front
Following inspections are necessary to detect these – Poor contact between terminal and wire
causes. • Damaged harness
• Improper connection of harness connector and – Visually check the harness for damage.
ECM connector
– Poor connection of terminal from connector display while moving the connector and the har-
– Unmatched terminals are fitted. ness which are related to the sensor. The varia-
– Damage of connector lock tion of the display indicates the faulty part.

Check the DTC.
seconds.
3. Check the DTC.
Go to “Diagnostic
0.45±0.1Ω
(20°C {68°F})

breaker box or DMM.
Note:
Codes”.
• Open circuit
• High resistance

nal nut.
etc.

nector.



• Open circuit
required.

tor.


Note:
service manual.

necessary.
Note:
11 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.



Name
1. Breaker box
2. DMM

4 Open circuit/ Resistance • Remove the cou- ECM (4H: 118, 6H: 100Ω or less 10 MΩ or
high resistance measurement pling connector. 114) – Coupling con- more
• Key switch “OFF” nector (H-94) terminal
(4H: No.6, 6H: No.7)

3
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
TSWG0197
4HK1
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

3 3
3 E-35 3 E-37 E-27 E-31
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

B+ B+

TSHK0031
6HK1

2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

No. 5 No. 6 No. 4 No. 2 No. 1 No. 3

B+ B+

TSWG0076
of 1 — 5 — 3 — 6 — 2 — 4.
4HK1
• Rough idling
6
• Output lowering
1

4 (4HK1).
(6HK1).
DTC set condition

TSHK0032
Name
1. Cylinder No. 1
4. Cylinder No. 4
6HK1
Back-up mode
8
1

3

4
6
TSWG0157
Name
2. Cylinder No. 2
8. Engine front
ECM connector

Check the DTC.
seconds.
3. Check the DTC.
Go to “Diagnostic
0.45±0.1Ω
(20°C {68°F})

breaker box or DMM.
Note:
Codes”.
• Open circuit
• High resistance

nal nut.
etc.

nector.



• Open circuit
required.

tor.


Note:
service manual.

necessary.
Note:
11 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.



Name
1. Breaker box
2. DMM

• Key switch “OFF” nector (H-94) terminal
(4H: No. 7, 6H: No. 6)

3
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
TSWG0197
4HK1
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

3 3
3 E-35 3 E-37 E-27 E-31
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

B+ B+

TSHK0031
6HK1
Key switch (ON)
(15A)*
Reguration
29 E-57 41 E-57 33 E-57 47 E-57 30 E-57 31 E-57 49 E-57 50 E-57 51 E-57
ECM
TSHK0143
of 1 — 5 — 3 — 6 — 2 — 4.
4HK1
• Rough idling
6
• Output lowering
1

4 (4HK1).
(6HK1).
DTC set condition

TSHK0032
Name
1. Cylinder No. 1
4. Cylinder No. 4
6HK1
Back-up mode
8
1

3

4
6
TSWG0157
Name
2. Cylinder No. 2
8. Engine front
ECM connector

Check the DTC.
seconds.
3. Check the DTC.
Go to “Diagnostic
2. Remove the coupling connector (4H: H-94, 6H:
H-95) from the cylinder head cover case.
0.45±0.1Ω
(20°C {68°F})

ECM and coupling connector (4H: H-94, 6H:
H-95) using breaker box or DMM.
Note:
Codes”.
• Open circuit
• High resistance

nal nut.
etc.

nector.



• Open circuit
required.

tor.


Note:
service manual.

necessary.
Note:
11 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.



Name
1. Breaker box
2. DMM

• Key switch “OFF” nector terminal
(4H: H-94 No. 8, 6H:
H-95 No. 2)

3
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
TSWG0197

2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

No. 5 No. 6 No. 4 No. 2 No. 1 No. 3

B+ B+

TSWG0076
Cylinder No. and injection order Action taken when DTC is set
8
1
2 Back-up mode
3
4
7 and “About recovery from failure” in this section for
5

TSWG0157
Name • The diagnosis lamp will go off after the code turns
1. Cylinder No. 1 to history trouble and the key switch is turned
2. Cylinder No. 2 “OFF” then “ON” again.
3. Cylinder No. 3 • Using the scan tool, or memory clear switch and
4. Cylinder No. 4 diagnostic switch operation enables to clear DTCs.
5. Cylinder No. 5
7. Cylinder block If the intermittent trouble is suspected, followings may
8. Engine front be the cause.
Fuel injection is performed to each cylinder in the order • Defective harness routing
of 1 — 5 — 3 — 6 — 2 — 4.
Main trouble symptom • Wire disconnection inside harness cladding
• Intense engine vibration causes.
• Rough idling • Improper connection of harness connector and
• Output lowering ECM connector
• Engine blow up fault – Poor connection of terminal from connector
• Main relay power supply voltage is 18V or more. – Poor contact between terminal and wire
• 70 rpm or more • Damaged harness
• DTC P0612, P1262, or P0205 is not detected. – Visually check the harness for damage.
DTC set condition
• Open/short circuit is detected in No. 5 cylinder ness which are related to the sensor. The varia-
injector drive circuit. tion of the display indicates the faulty part.


Check the DTC.
seconds.
3. Check the DTC.
Go to “Diagnostic
3. Measure the resistance between the coupling 0.45±0.1Ω
3
(20°C {68°F})

breaker box or DMM.
Note:
Codes”.
• Open circuit
• High resistance

nal nut.
etc.

nector.


• Open circuit
required.


tor.


Note:
service manual.

necessary.
Note:
11 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

Name
1. Breaker box
2. DMM

high resistance measurement pling connector. nector (H-95) No. 7 more
• Key switch “OFF” terminal
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness


2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

No. 5 No. 6 No. 4 No. 2 No. 1 No. 3

B+ B+

TSWG0076
Cylinder No. and injection order Action taken when DTC is set
8
1
2 Back-up mode
3
4
7 and “About recovery from failure” in this section for
5

TSWG0157
Name • The diagnosis lamp will go off after the code turns
1. Cylinder No. 1 to history trouble and the key switch is turned
2. Cylinder No. 2 “OFF” then “ON” again.
3. Cylinder No. 3 • Using the scan tool, or memory clear switch and
4. Cylinder No. 4 diagnostic switch operation enables to clear DTCs.
5. Cylinder No. 5
7. Cylinder block If the intermittent trouble is suspected, followings may
8. Engine front be the cause.
Fuel injection is performed to each cylinder in the order • Defective harness routing
of 1 — 5 — 3 — 6 — 2 — 4.
Main trouble symptom • Wire disconnection inside harness cladding
• Intense engine vibration causes.
• Rough idling • Improper connection of harness connector and
• Output lowering ECM connector
• Engine blow up fault – Poor connection of terminal from connector
• Main relay power supply voltage is 18V or more. – Poor contact between terminal and wire
• 70 rpm or more • Damaged harness
• DTC P0612, P1262, or P0206 is not detected. – Visually check the harness for damage.
DTC set condition
• Open/short circuit is detected in No. 6 cylinder ness which are related to the sensor. The varia-
injector drive circuit. tion of the display indicates the faulty part.


Check the DTC.
seconds.
3. Check the DTC.
Go to “Diagnostic
3. Measure the resistance between the coupling 0.45±0.1Ω
3
(20°C {68°F})

breaker box or DMM.
Note:
Codes”.
• Open circuit
• High resistance

nal nut.
etc.

nector.


• Open circuit
required.


tor.


Note:
service manual.

necessary.
Note:
11 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

Name
1. Breaker box
2. DMM

high resistance measurement pling connector. nector (H-95) No. 6 more
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

DTC: P0219 (Flash code 543) Overrun
Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V
CKP CKP
HIGH LOW
signal signal
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 2 H-20 1 H-20
0.75 Br
0.75 0.75 0.75

0.75 0.75
W/R B/W Br
B/R W/L
2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W
CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSHK0033
Description of circuit Action taken when DTC is set

The engine control module (ECM) detects the engine • Trouble is displayed on the monitor of the
speed based on the crankshaft position (CKP) sensor machine or diagnosis lamp comes on.
signal. The ECM stops the fuel injection to lower the
engine speed when the engine speed exceeds the
specified value.
Back-up mode
Main trouble symptom • Limited injection amount 1
Output lowering • Limitation is lifted if the speed decreases
Preconditions when DTC is set Recovery from failure

• Key switch input voltage is 18V or more. Refer to 1E-284, “List of Diagnostic Trouble Codes”
DTC set condition recovery from failure.
• The engine speed exceeds setting value for 1
second or more
The conditions to clear the MIL/DTC • Crankshaft position (CKP) sensor, camshaft posi-
tion (CMP) sensor fault (signal fault etc.)
the condition is out of the range from DTC set con- • Engine body fault (supply pump, injector, body,
dition (recovery from failure). etc.)
• The diagnosis lamp will go off after the code turns • ECM internal trouble
to history trouble and the key switch is turned • Check the connector for poor contact, the harness
“OFF” then “ON” again. for fault such as wear or bend, and the wire inside
• Using the scan tool, or memory clear switch and the harness for loosened wire causing short circuit
diagnostic switch operation enables to clear DTCs. to other circuits. Also, perform the function diagno-
sis to check the operation and control of each part.
Diagnostic aid Repair if faulty.
• Load (fluid pressure pump etc.) is light. • When this DTC is detected, check the engine body
for trouble such as seizure and breakage.

Confirm the driving status (improper operation of
the vehicle due to engine over speed). (Interview
2 the operator for driving status in the past.) —
Has the vehicle been operated improperly? Go to Step 3. Go to Step 4.

Tell the operator that it is the over speed caused by
3 improper operation, and give a driving instruction. —
Check for adverse effect (fault in the engine body)
caused by the engine over speed. Repair or
4 replace if fault is found. —

1. Clear the DTC.
clear DTCs.

seconds.
set”.
4. Check the DTC.
Go to each DTC
Is DTC detected? diagnosis. Verify repair.
DTC: P0237 (Flash code 32) Boost sensor pressure fault (low voltage fault, open circuit)
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
74 E-56 109 E-56 91 E-56 95 E-56
15 H-20 17 H-20 16 H-20 8 H-20
0.75 0.75 0.75 0.75 0.75

B/R R/L R/L L R/W
2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

TSWG0079
Description of circuit The ECM sets the DTC when the signal voltage from
The boost pressure sensor is installed to the intake the boost pressure sensor is less than the normal
manifold. The boost pressure sensor outputs the volt- range.
age corresponding to the internal pressure of the intake
manifold, and the ECM detects the boost by this signal. Main trouble symptom
The boost pressure sensor includes following circuits. Black smoke emitted
• 5-V power supply circuit
• Ground circuit
• Boost pressure sensor signal circuit • Key switch input voltage is 18V or more.
The ECM provides 5 V to the boost pressure sensor • DTC P1630 or P1634 is not detected.
through 5-V power supply circuit, and grounds to the
inside of the ECM through ground circuit. Also, the DTC set condition
boost pressure sensor outputs the signal voltage to the • Boost pressure sensor voltage is 0.1V or less for 3
ECM through boost pressure sensor signal circuit. The seconds or more.
ECM detects a low boost condition (the engine load is
low) when the signal voltage from the boost pressure
sensor is low, and a high boost condition (the engine
load is high) when the signal voltage from the boost
pressure sensor is high.
causes.
Back-up mode
• Specified back-up value (4HK1) ECM connector
• Boost pressure default setting (150 MPa {21756 – Poor connection of terminal from connector
psi}) (6HK1) – Unmatched terminals are fitted.
• Boost pressure correction/EGR stopped (6HK1) – Damage of connector lock
Recovery from failure • Damaged harness
Refer to 1E-284, “List of Diagnostic Trouble Codes” – Visually check the harness for damage.
and “About recovery from failure” in this section for – Check the relevant items on the scan tool data
recovery from failure. display while moving the connector and the har-
The conditions to clear the MIL/DTC tion of the display indicates the faulty part.
Test description
dition (recovery from failure). Numbers below indicate step numbers in the chart.
• The diagnosis lamp will go off after the code turns 3. In case of present trouble, the “MAP (manifold abso-
to history trouble and the key switch is turned lute pressure) sensor” displays less than the threshold
“OFF” then “ON” again. value. If more than the threshold value, identify the
cause by referring to “Diagnostic aid”.
• Using the scan tool, or memory clear switch and 5. If “MAP (manifold absolute pressure) sensor” dis-
diagnostic switch operation enables to clear DTCs. plays more than the specified value when terminals
between the boost pressure sensor connector are
Diagnostic aid shorted, the circuit beyond the sensor is normal includ-
If the intermittent trouble is suspected, followings may ing ECM.
be the cause.

2. Check for “MAP (manifold absolute pressure)
3 sensor” on the data display using scan tool. 0.1V
Is the “MAP (manifold absolute pressure) sensor” Go to “Diagnostic
less than the threshold value? Go to Step 4. aid”.
Check for installation condition of the boost pres-
sure sensor connector, ECM connector and cou-
pling connector.


2. Disconnect the boost pressure sensor connec-
tor.
3. Short between the boost pressure sensor con-
nector power supply terminal and the signal
5 terminal using jump cable. 4.8V
sensor” on the data display using scan tool.
Is the “MAP (manifold absolute pressure) sensor”

more than the specified value? Go to Step 8. Go to Step 6.
between ECM and boost pressure sensor
cedure, DTC: P0237 (Flash code 32) Boost
sensor pressure fault (low voltage fault, open
circuit), List of Diagnostic Trouble Codes”.
Note:
P0237 (Flash code 32) Boost sensor pressure fault
(low voltage fault, open circuit), List of Diagnostic
Trouble Codes”.
• Open circuit
• High resistance

Note:
7 P0237 (Flash code 32) Boost sensor pressure fault —
Trouble Codes”.
• Short circuit to boost pressure sensor
ground circuit
• Open circuit
• High resistance

Replace the boost pressure sensor.
8 —

necessary.
Note:
10 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

2. Check the display of boost pressure sensor. 508 MPa
14 (73679 psi)
Does the display of “Boost pressure sensor” show (error value) Go to “Diagnostic
pling connector.


Note:
P0237 (Flash code 32) Boost sensor pressure fault
Trouble Codes”.
• Open circuit
• High resistance

Note:
17 P0237 (Flash code 32) Boost sensor pressure fault —
Trouble Codes”.
• Short circuit to boost pressure sensor
ground circuit
• Open circuit
• High resistance

About boost pressure sensor
(V)
4.75026
3 2 1
0.100082
40(5802) 350(50763)
MPa(psi)
TSWG0063
TSWG0062
Name
1. Sensor ground Perform the inspection in the following procedure if
2. Sensor signal there is such an instruction to use breaker box in the
3. Sensor power supply step. After inspection, return to the diagnostic step.
Characteristics of boost pressure sensor

The output voltage of boost pressure sensor changes
according to the boost pressure. The scan tool with
as it is more than the threshold value if the value of 40
MPa (5802 psi) or 350 MPa (50763 psi) is not changed.
When error occurs, error value (508 MPa {73679 psi})
is displayed.
Name
1. Breaker box
2. DMM

2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault, short to
power supply circuit, ground open circuit)
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
74 E-56 109 E-56 91 E-56 95 E-56
15 H-20 17 H-20 16 H-20 8 H-20
0.75 0.75 0.75 0.75 0.75

B/R R/L R/L L R/W
2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

TSWG0079
Description of circuit The ECM provides 5 V to the boost pressure sensor

through 5-V power supply circuit, and grounds to the
The boost pressure sensor is installed to the intake
inside of the ECM through ground circuit. Also, the
manifold. The boost pressure sensor outputs the volt-
boost pressure sensor outputs the signal voltage to the
age corresponding to the internal pressure of the intake
ECM through boost pressure sensor signal circuit. The
manifold, and the ECM detects the boost by this signal.
The boost pressure sensor includes following circuits. ECM detects a low boost condition (the engine load is
low) when the signal voltage from the boost pressure
• 5-V power supply circuit sensor is low, and a high boost condition (the engine
• Ground circuit load is high) when the signal voltage from the boost
• Boost pressure sensor signal circuit pressure sensor is high.
The ECM sets the DTC when the signal voltage from
the boost pressure sensor is more than the normal
range.

Black smoke emitted
Preconditions when DTC is set Diagnostic aid
• Key switch input voltage is 18V or more. If the intermittent trouble is suspected, followings may
• DTC P1630 or P1634 is not detected. be the cause.
DTC set condition • Defective harness routing
• Boost pressure sensor voltage is 4.9V or more for • Worn harness cladding
3 seconds or more. • Wire disconnection inside harness cladding
Action taken when DTC is set causes.
• Trouble is displayed on the monitor of the • Improper connection of harness connector and
machine or diagnosis lamp comes on. ECM connector
Back-up mode – Damage of connector lock
• Specified back-up value (4HK1) – Poor contact between terminal and wire
• Boost pressure default setting (150 MPa {21756 • Damaged harness
psi}) (6HK1) – Visually check the harness for damage.
• Boost pressure correction/EGR stopped (6HK1) – Check the relevant items on the scan tool data
Recovery from failure tion of the display indicates the faulty part.
Test description
recovery from failure. Numbers below indicate step numbers in the chart.
3. In case of present trouble, the “MAP (manifold abso-
The conditions to clear the MIL/DTC lute pressure) sensor” displays more than the specified
value. If less than the specified value, identify the
cause by referring to “Diagnostic aid”.
5. If “MAP (manifold absolute pressure) sensor” dis-
plays less than the specified value when the boost
• The diagnosis lamp turns off when the trouble pressure sensor connector is removed, the circuit
code turns to the history trouble. beyond the sensor is normal including ECM.
diagnostic switch operation enables to clear history
trouble.

3 sensor” on the data display using scan tool. 4.9V
Is the “MAP (manifold absolute pressure) sensor” Go to “Diagnostic
more than the specified value? Go to Step 4. aid”.
pling connector.


tor.
5 0.1V
sensor” on the data display using scan tool.
Is the “MAP (manifold absolute pressure) sensor”

less than the specified value? Go to Step 8. Go to Step 6.
boost pressure sensor for short circuit to the
power supply circuit or ignition power supply
circuit using breaker box or DMM.
pressure sensor fault (high voltage fault, short
to power supply circuit, ground open circuit),
Note:
P0238 (Flash code 32) Boost pressure sensor fault
(high voltage fault, short to power supply circuit,
ground open circuit), List of Diagnostic Trouble
Codes”.
Important:
If the boost pressure sensor circuit is shorted
to the power supply circuit, the sensor may be
broken.

Note:
Codes”.
• Open circuit
• High resistance

Replace the boost pressure sensor.
8 —

necessary.
Note:
10 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

2. Check the display of boost pressure sensor. 508 MPa
14 (73679 psi)
Does the display of “Boost pressure sensor” show (error value) Go to “Diagnostic
pling connector.


boost pressure sensor for short circuit to the
Note:
Codes”.
Important:
If the boost pressure sensor circuit is shorted
to the power supply circuit, the sensor may be
broken.

Note:
Codes”.
• Open circuit
• High resistance

About boost pressure sensor
(V)
4.75026
3 2 1
0.100082
40(5802) 350(50763)
MPa(psi)
TSWG0063
TSWG0062
Name
Characteristics of boost pressure sensor

The output voltage of boost pressure sensor changes
according to the boost pressure. The scan tool with
as it is more than the threshold value if the value of 40
MPa (5802 psi) or 350 MPa (50763 psi) is not changed.
When error occurs, error value (508 MPa {73679 psi})
is displayed.
Name
1. Breaker box
2. DMM

7, 17 Open circuit/ Resistance • Disconnect the 109 – Sensor connec- 100Ω or less 10 MΩ or
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0335 (Flash code 15) Crank sensor fault (no signal)
Engine control
module(ECM)
5V
CKP CKP
HIGH LOW
signal signal
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 2 H-20 1 H-20
0.75 Br
0.75 0.75 0.75

0.75 0.75
W/R B/W Br
B/R W/L
2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W
CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSHK0033
Description of circuit • DTC P0335, P0336, P0340, P0341, or P1345 is

The crankshaft position (CKP) sensor detects the not detected.
engine speed. When the sensing hole installed in the • Engine under operation
flywheel passes the tip of the CKP sensor, a voltage is
generated and turned into a pulse signal. The engine DTC set condition
control module (ECM) reads this pulse signal, and • Cam signal exists but no crank signal.
obtains the engine speed and injection timing based on
the signal. Action taken when DTC is set
Main trouble symptom • Trouble is displayed on the monitor of the
• Output lowering
• White smoke emitted
• Intense engine vibration possible
• Engine stall possible (restart is possible when
Back-up mode
camshaft position sensor is normal.) • Control based on cam when cam sensor is normal

• Cam pulse is normal.
Refer to 1E-284, “List of Diagnostic Trouble Codes” – Unmatched terminals are fitted.
• Damaged harness
“OFF” then “ON” again. • For crank sensor fault, DTC won’t be detected
unless the engine cranks for 14 revolutions. Espe-
• Using the scan tool, or memory clear switch and cially when running with low speed such as idling,
diagnostic switch operation enables to clear DTCs. engine stalls before cranking for 14 revolutions if
no crank signal exist. In this case, the back-up
Diagnostic aid mode will not be active because DTC is not
If the intermittent trouble is suspected, followings may detected. Therefore, the engine can be restarted
be the cause. even after it stalls, making it difficult to identify the
• Improper connection of harness connector fault. If the engine experienced stall, raise the
engine speed up to No Load Max, and check if
crank sensor fault is detected while cranking for 14
• Worn harness cladding revolutions. If crank sensor fault is detected at No
• Wire disconnection inside harness cladding Load Max, DTC will be detected. If intermittent
Following inspections are necessary to detect these trouble is found, raise the engine speed up to No
causes. Load Max, and check if DTC is detected.
ECM connector

Check for installation condition of the crankshaft
position (CKP) sensor.
2 2. Visually check the sensor for installation condi- —
tion such as play or looseness.

Check for installation condition of the CKP sensor,
required.


1. Clear the DTC.
clear DTCs.

seconds.
4. Check the DTC.
Is DTC detected? Go to Step 5. Go to Step 12.

Check the CKP sensor body. Between termi-
1. Turn the key switch to “OFF”. nals: 108.5 —
2. Remove the harness from the CKP sensor. 142.5 Ω; Each
5 terminal —
3. Measure the resistance between the sensor
ground: ∞ Ω (at
connector terminals.
normal temper-
Is the resistance within the specified value? ature) Go to Step 6. Go to Step 7.
ECM and CKP sensor using breaker box or
DMM.
cedure, DTC: P0335 (Flash code 15) Crank
sensor fault (no signal), List of Diagnostic
Trouble Codes”.
Note:
P0335 (Flash code 15) Crank sensor fault (no sig-
6 nal), List of Diagnostic Trouble Codes”. —
• Open circuit
• High resistance
• Short circuit between terminals
• Short circuit to power supply circuit or igni-
tion power supply circuit
required.

Replace the CKP sensor.
7 —
necessary.
Note:
9 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

About CKP sensor 4HK1
TSHK0128
TSWG0064
Name
1. GND
2. Power supply
6HK1 6HK1
TSHK0129 TSWG0151
Name
About CKP sensor and CMP sensor signals 1. CKP signal
4HK1 2. CMP signal

TSHK0042
Name
1. Breaker box
2. DMM

high resistance measurement sensor connector. tor (−) terminal more
• Key switch “OFF” 107 – Sensor connec-
tor (+) terminal
ground measurement sensor connector. 107 – Ground more
Short circuit Resistance • Disconnect the 106 – 107 10 MΩ or 100Ω or less
between termi- measurement sensor connector. more
nals • Key switch “OFF”
power supply surement sensor connector. 107 – Ground
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0336 (Flash code 15) Crank sensor fault (signal fault)
Engine control
module(ECM)
5V
CKP CKP
HIGH LOW
signal signal
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 2 H-20 1 H-20
0.75 Br
0.75 0.75 0.75

0.75 0.75
W/R B/W Br
B/R W/L
2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W
CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSHK0033
Description of circuit • DTC P0335, P0336, P0340, P0341, or P1345 is

The crankshaft position (CKP) sensor detects the not detected.
engine speed. When the sensing hole installed in the • Engine under operation
flywheel housing passes the tip of the CKP sensor, a
voltage is generated and turned into a pulse signal. The DTC set condition
engine control module (ECM) reads this pulse signal, • Number of pulse for crank signal is mismatched.
and obtains the engine speed and injection timing
based on the signal. Action taken when DTC is set
• Output lowering
• White smoke emitted
• Intense engine vibration possible
• Engine stall possible (restart is possible when
Back-up mode
camshaft position sensor is normal.) • Control based on cam when cam sensor is normal

• Cam pulse is normal.
Refer to 1E-284, “List of Diagnostic Trouble Codes” – Unmatched terminals are fitted.
• Damaged harness
“OFF” then “ON” again. • For crank sensor fault, DTC won’t be detected
unless the engine cranks for 14 revolutions. Espe-
• Using the scan tool, or memory clear switch and cially when running with low speed such as idling,
diagnostic switch operation enables to clear DTCs. engine stalls before cranking for 14 revolutions if
no crank signal exist. In this case, the back-up
Diagnostic aid mode will not be active because DTC is not
If the intermittent trouble is suspected, followings may detected. Therefore, the engine can be restarted
be the cause. even after it stalls, making it difficult to identify the
• Improper connection of harness connector fault. If the engine experienced stall, raise the
engine speed up to No Load Max, and check if
crank sensor fault is detected while cranking for 14
• Worn harness cladding revolutions. If crank sensor fault is detected at No
• Wire disconnection inside harness cladding Load Max, DTC will be detected. If intermittent
Following inspections are necessary to detect these trouble is found, raise the engine speed up to No
causes. Load Max, and check if DTC is detected.
ECM connector

position (CKP) sensor.
2 2. Visually check the sensor for installation condi- —
tion such as play or looseness.

Check for installation condition of the CKP sensor,
required.


1. Clear the DTC.
clear DTCs.

seconds.
4. Check the DTC.

1. Check the CKP sensor circuit for short circuit
to other signal circuit using breaker box or
DMM.
cedure, DTC: P0336 (Flash code 15) Crank
sensor fault (signal fault), List of Diagnostic
Trouble Codes”.
5 Note: —
P0336 (Flash code 15) Crank sensor fault (signal
required.

Check the CKP sensor body.
1. Turn the key switch to “OFF”. Between termi-
2. Remove the harness from the CKP sensor. nals: 108.5 —
3. Measure the resistance between the sensor 142.5 Ω; Each
6 terminal —
connector terminals.
ground: ∞ Ω (at
4. Remove the CKP sensor, and check the sen- normal temper-
sor tip for scratch or damage. ature)
Is the CKP sensor normal? Go to Step 8. Go to Step 7.
Replace the CKP sensor.
7 —
1. Visually check the flywheel for chipped tooth.
8 2. If the trouble is detected, replace it. —
necessary.
Note:
10 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

TSHK0128
TSWG0064
Name
1. GND
2. Power supply
6HK1 6HK1
TSHK0129 TSWG0151
Name
About CKP sensor and CMP sensor signals 1. CKP signal
4HK1 2. CMP signal

TSHK0042
Name
1. Breaker box
2. DMM

2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0340 (Flash code 14) Cam sensor fault (no signal)
Engine control
module(ECM)
5V
CKP CKP
HIGH LOW
signal signal
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 2 H-20 1 H-20
0.75 Br
0.75 0.75 0.75

0.75 0.75
W/R B/W Br
B/R W/L
2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W
CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSHK0033
Description of circuit DTC set condition

The camshaft position (CMP) sensor detects the cam- • Crank signal exists but no cam signal.
shaft rotation and identifies the cylinder. When the pul-
sar installed in the camshaft passes the tip of the Action taken when DTC is set
camshaft position (CMP) sensor, a voltage is gener-
ated and turned into a pulse signal. The engine control
module (ECM) reads this pulse signal, and identifies
the cylinder based on the signal.

• Engine does not start (restart).
• Engine running based on crank when it is normal
• Behavior does not change during engine running. • After engine stops: Unable to identify cylinder
(unable to restart)
• Crank pulse is normal. Recovery from failure
• DTC P0335, P0336, P0340, P0341, P1345, or Refer to 1E-284, “List of Diagnostic Trouble Codes”
P1635 is not detected. and “About recovery from failure” in this section for
• Engine under operation recovery from failure.
The conditions to clear the MIL/DTC • Wire disconnection inside harness cladding
causes.
dition (recovery from failure). • Improper connection of harness connector and
ECM connector
to history trouble and the key switch is turned – Poor connection of terminal from connector
“OFF” then “ON” again. – Unmatched terminals are fitted.
• Using the scan tool, or memory clear switch and – Damage of connector lock
diagnostic switch operation enables to clear DTCs. – Poor contact between terminal and wire
• Damaged harness
Diagnostic aid
be the cause. – Check the relevant items on the scan tool data
• Worn harness cladding • The cam gears are out of installation phase by one
tooth.

Check for installation condition of the CMP sensor.
2. Visually check the sensor for installation condi-
2 tion such as play or looseness. —

Check for installation condition of the CMP sensor,
3 —
required.

1. Clear the DTC.
clear DTCs.

seconds.
4. Check the DTC.

Remove the CMP sensor, and check the sensor tip
5 for scratch or damage. —
Is the CMP sensor normal? Go to Step 6. Go to Step 9.

between ECM and CMP sensor using breaker
box or DMM.
cedure, DTC: P0340 (Flash code 14) Cam
Trouble Codes”.
Note:
P0340 (Flash code 14) Cam sensor fault (no sig-
nal), List of Diagnostic Trouble Codes”.
• Open circuit
• High resistance
required.

box or DMM.
Trouble Codes”.
Note:
7 P0340 (Flash code 14) Cam sensor fault (no sig- —
• Open circuit
• High resistance
required.

1. Check for followings in the shield circuit
box or DMM.
Trouble Codes”.
Note:
8 P0340 (Flash code 14) Cam sensor fault (no sig- —
• Open circuit
• High resistance
required.


Replace the CMP sensor.
9 —
1. Visually check the camshaft gear for fault.
2. Check the alignment mark in the timing gear.
10 —
3. If the trouble is detected, repair or replace it.

necessary.
Note:
12 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

About camshaft position (CMP) sensor 6HK1
15
TSWG0152
Name
Name 1. CMP sensor
1. Shield
2. −
3. + About CKP sensor and CMP sensor signals
4HK1
4HK1
15
1
TSHK0042
TSHK0040
6HK1 Breaker box inspection procedure
TSWG0151
Name
1. CKP signal
2. CMP signal
Name
1. Breaker box
2. DMM

ground measurement sensor connector. more
high resistance measurement sensor connector. tor shield terminal more
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0341 (Flash code 14) Cam sensor fault (signal fault)
Engine control
module(ECM)
5V
CKP CKP
HIGH LOW
signal signal
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 2 H-20 1 H-20
0.75 Br
0.75 0.75 0.75

0.75 0.75
W/R B/W Br
B/R W/L
2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W
CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSHK0033

The camshaft position (CMP) sensor detects the cam- • Number of pulse for cam signal is mismatched.
shaft rotation and identifies the cylinder. When the pul-
sar installed in the camshaft passes the tip of the CMP Action taken when DTC is set
sensor, a voltage is generated and turned into a pulse
signal. The engine control module (ECM) reads this
pulse signal, and identifies the cylinder based on the
signal.

• Engine does not start (restart).
• Engine running based on crank when it is normal
• Behavior does not change during engine running. • After engine stops: Unable to identify cylinder
(unable to restart)
• Crank pulse is normal. Recovery from failure
• DTC P0335, P0336, P0340, P0341, P1345, or Refer to 1E-284, “List of Diagnostic Trouble Codes”
P1635 is not detected. and “About recovery from failure” in this section for
• Engine under operation recovery from failure.
The conditions to clear the MIL/DTC • Wire disconnection inside harness cladding
causes.
dition (recovery from failure). • Improper connection of harness connector and
ECM connector
to history trouble and the key switch is turned – Poor connection of terminal from connector
“OFF” then “ON” again. – Unmatched terminals are fitted.
• Damaged harness
Diagnostic aid

Check for installation condition of the CMP sensor.
2. Visually check the sensor for installation condi-
2 tion such as play or looseness. —

Check for installation condition of the CMP sensor,
3 —
required.

1. Clear the DTC.
clear DTCs.

seconds.
4. Check the DTC.

Remove the CMP sensor, and check the sensor tip
5 for scratch or damage. —
Is the CMP sensor normal? Go to Step 6. Go to Step 8.

2. Remove the harness from the CMP sensor.
3. Connect the breaker box or DMM between the
CMP sensor terminals.
Trouble Codes”.
6 0V
Note:
P0341 (Flash code 14) Cam sensor fault (signal
Is the DMM indication specified value? Go to Step 8. Go to Step 7.

1. Check the CMP sensor circuit for short circuit
to other signal circuit using breaker box or
DMM.
Trouble Codes”.
7 Note: —
P0341 (Flash code 14) Cam sensor fault (signal
required.

Replace the CMP sensor.
8 —
1. Visually check the camshaft gear for fault.
2. Check the alignment mark in the timing gear.
9 —
3. If the trouble is detected, repair or replace it.

Note:
service manual.


necessary.
Note:
12 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

About CMP sensor Name

1. Shield
2. −
3. +
4HK1 About CKP sensor and CMP sensor signals
4HK1
15
1
1
TSHK0040
6HK1 TSHK0042
6HK1
15
1
1
TSWG0152
Name
TSWG0151
1. CMP sensor
Name
1. CKP signal
2. CMP signal
Name
1. Breaker box
2. DMM

circuit • Key switch “OFF”
other signal cir- surement sensor connector.
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness
DTC: P0380 (Flash code 66) Glow relay circuit fault
(100A)*
Starter
B
Battery B
Generator
(15A)*
(60A)*
Glow Starter Starter

relay cut relay cut relay Main relay
(10A)*
1 H-22
0.5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START
Glow Glow relay Engine

plug control control
module
(ECM)
Starter cut
relay signal
TSWG0072
Note: DTC set condition

The QOS circuit is the same for both the starter ECM
• No glow relay monitor signal exists against glow
control specifications and the safety relay specifica-
relay drive instruction signal.
tions.
The glow relay cuts off the power supply voltage (24 V)
to the glow plug, and turns “ON” when the signal from
ECM is input. The ECM recognizes the starter switch
“ON” signal, and outputs the “ON” signal to the glow
relay.
Back-up mode
Main trouble symptom No back-up action
• Deterioration of startability
Preconditions when DTC is set Refer to 1E-284, “List of Diagnostic Trouble Codes”
• Key switch input power supply voltage is 16 V or
more and 32 V or less.
The conditions to clear the MIL/DTC – Poor connection of terminal from connector
• The present trouble turns to history trouble when – Unmatched terminals are fitted.
the condition is out of the range from DTC set con- – Damage of connector lock
dition (recovery from failure). – Poor contact between terminal and wire
• The diagnosis lamp turns off when the trouble • Damaged harness
code turns to the history trouble.
• Using the scan tool, or accelerator pedal operation
enables to clear history trouble.
Diagnostic aid
be the cause. Test description
• Improper connection of harness connector Numbers below indicate step numbers in the chart.
• Defective harness routing 6. If the “Glow relay” displays “ON” when terminals
• Worn harness cladding between the glow relay are shorted, the circuit beyond
the relay is normal including ECM.
9. If the “Glow relay” displays “OFF” when the glow
relay is removed, the circuit beyond the relay is normal
causes.
including ECM.
ECM connector

1. Turn the key switch to ON position.
2. Check for “Glow relay” on the data display
3 using scan tool. —
Is the “Glow relay” displayed “ON”? Go to Step 4. Go to Step 5.

1. Turn the key switch to ON position.
2. Hold it for more than 10 seconds.
4 3. Check for “Glow relay” on the data display —
using scan tool.
Go to “Diagnostic
Is the “Glow relay” displayed “OFF”? aid”. Go to Step 9.
Check for installation condition of the glow relay,
ECM connector and coupling connector.


2. Remove the glow relay.
3. Short between the terminals 2 - 4 in the glow
relay installing portion using jump cable.
6 4. Turn the key switch to “ON”. —

using scan tool.
Is the “Glow relay” displayed “ON”? Go to Step 11. Go to Step 7.


1. Check for following in the circuit between the
fuse and the glow relay.
• Open circuit
7 • Short circuit to ground circuit —

• High resistance

glow relay and ECM using breaker box or
DMM.
cedure, DTC: P0380 (Flash code 66) Glow
relay circuit fault, List of Diagnostic Trouble
Codes”.
Note:
P0380 (Flash code 66) Glow relay circuit fault, List
• Open circuit
• Short circuit to ground circuit
• High resistance

2. Remove the glow relay.
9 —
using scan tool.
Is the “Glow relay” displayed “OFF”? Go to Step 11. Go to Step 10.

1. Check the circuit between glow relay and ECM
for short circuit to the power supply circuit or
ignition power supply circuit using breaker box
or DMM.
relay circuit fault, List of Diagnostic Trouble
Codes”.
10 —
Note:
P0380 (Flash code 66) Glow relay circuit fault, List

Replace the glow relay.
11 —

necessary.
Note:
13 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

Check for installation condition of the glow relay,


Name
1. Breaker box
2. DMM

8 Open circuit/ Resistance • Disconnect the 10 – FL12 connector 10MΩ or 10 MΩ or
high resistance measurement relay. No. 1 terminal less more
Short circuit to Resistance • Disconnect the 10 – Ground 10 MΩ or 10MΩ or
ground measurement relay. more less
power supply surement relay.

3
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
TSWG0197
DTC: P0381 (Flash code 67) Glow plug lamp circuit fault
(15A)*
A A
Meter
Tachometer
Boost
3 H-6
1 E-164
Machine
CAN LOW CAN HIGH

Generator
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 8 E-57

Engine control
module (ECM)
Engine oil
Tachometer signal
CAN HIGH CAN LOW
TSHK0022

The QOS indicator lamp is installed in the meter. The • Glow lamp indication signal is unmatched with
engine control module (ECM) turns the QOS indicator glow lamp monitor signal.
lamp on to tell the glow plug operation when the key
switch is turned “ON”. The ECM detects the glow plug Action taken when DTC is set
operating condition, and turns the lamp off upon com- • Trouble is displayed on the monitor of the
pletion of preheat. machine or diagnosis lamp comes on.
Operationality is not affected.
Back-up mode
Preconditions when DTC is set • No back-up action
• Key switch input voltage is 18V or more.
• DTC P0381 is not detected. Recovery from failure
The conditions to clear the MIL/DTC – Unmatched terminals are fitted.
• The present trouble turns to history trouble when – Damage of connector lock
the condition is out of the range from DTC set con- – Poor contact between terminal and wire
dition (recovery from failure). • Damaged harness
• The diagnosis lamp will go off after the code turns – Visually check the harness for damage.

If the intermittent trouble is suspected, followings may Numbers below indicate step numbers in the chart.
be the cause. 2. If the lamp does not come on with the key switch
• Blown lamp bulb “ON”, open circuit, short circuit to the ground circuit,
• Improper connection of harness connector blown light bulb, or ECM fault is suspected.
2. If the lamp does not go OFF, short circuit to the
ground circuit, meter circuit fault, or ECM fault is sus-
• Worn harness cladding pected.
• Wire disconnection inside harness cladding 4. If the lamp goes off when the ECM connector is
Following inspections are necessary to detect these removed, the circuit beyond the ECM is normal includ-
causes. ing meter.
• Improper connection of harness connector and 7. If the lamp comes on when the lamp control terminal
ECM connector is shorted to the ground, the circuit beyond the ECM is
– Poor connection of terminal from connector normal including meter.

2 2. Check if the QOS indicator lamp is ON. —
Turn the key switch “ON” and wait for 10 seconds. Go to “Diagnostic
3 —
Does the QOS indicator lamp go OFF? aid”. Go to Step 4.
2. Remove the connector from the ECM.
4. Check if the QOS indicator lamp is ON.
Does the QOS indicator lamp go OFF? Go to Step 12. Go to Step 5.

Check for installation condition of the meter, ECM
connector and coupling connector.



1. Check the circuit between QOS indicator lamp
and ECM for ground short circuit using breaker
box or DMM.
plug lamp circuit fault, List of Diagnostic Trou-
ble Codes”.
6 Note: —
P0381 (Flash code 67) Glow plug lamp circuit fault,

3. Short between the QOS indicator lamp control
terminal of the ECM and the ground using
breaker box.
ble Codes”.
7 —
Note:
5. Check if the QOS indicator lamp is ON.


fuse and the QOS indicator lamp.
• Open circuit
• High resistance


QOS indicator lamp and ECM using breaker
box or DMM.
ble Codes”.
Note:
• Open circuit
• High resistance

Replace the meter.
11 —
Replace the QOS indicator lamp bulb.
12 —
necessary.
Note:
14 —

Replace the ECM.
Note:

Check if DTC is not detected again.
2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.


Check if DTC is detected. (DTC for entire engine
control) Go to the related
17 — “Inspection method
Is DTC detected? by DTC”. Verify repair.

Name
1. Breaker box
2. DMM
Step Item to be Inspection Measuring condition Terminal No. Normal value Abnormal
checked method value
6 Short circuit to Resistance • Remove the meter 11 – Ground 10 MΩ or 10MΩ or less
ground measurement connector. more
7 Open circuit/ Lamp ON • Remove the ECM. Short the terminal Lamp ON Lamp OFF
high resistance • Key switch “ON” No. 11 with ground
circuit.
10 Open circuit/ Resistance • Remove the meter 11 – Meter connector 10MΩ or less 10 MΩ or
high resistance measurement connector. QOS indicator lamp more
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0487 (Flash code 44) EGR position sensor fault
Engine control
module (ECM)
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR valve
TSHK0028
Description of circuit The ECM provides 5 V to the EGR position sensors U,

The EGR position sensor is installed inside the EGR V, and W through 5-V power supply circuit, and
valve. The EGR position sensor is the hall IC type sen- grounds to the inside of the ECM through ground cir-
sor and is installed to 3 locations. It detects the motor cuit. Also, the EGR position sensor outputs polarity
phase based on each polarity output (ON/OFF). The (ON/OFF) of any one of the EGR position sensors U, V,
EGR position sensor includes following circuits. and W through respective signal circuit, to the ECM.
The ECM detects the EGR valve position by counting
• 5-V power supply circuit the number of change in polarity.
• Ground circuit The ECM sets the DTC when all of the EGR position
• EGR position sensor U signal circuit sensors U, V, and W output “ON” or “OFF” simulta-
• EGR position sensor V signal circuit neously.
• EGR position sensor W signal circuit
Exhaust gas is affected.

• Main relay input voltage is 18 V or more.
• DTC P1630 or P1635 is not detected.
DTC set condition Diagnostic aid
• Input signals from EGR position sensors U, V, and If the intermittent trouble is suspected, followings may
W are all ON or all OFF for 3 seconds or more. be the cause.
Action taken when DTC is set • Defective harness routing
• Trouble is displayed on the monitor of the • Worn harness cladding
causes.
Back-up mode • Improper connection of harness connector and
ECM connector
• Instruction to fully close EGR valve
to history trouble and the key switch is turned Test description
“OFF” then “ON” again. Numbers below indicate step numbers in the chart.
• Using the scan tool, or memory clear switch and 3. Check all the signal circuits of the EGR position sen-
diagnostic switch operation enables to clear DTCs. sors U, V, and W.

Check for installation condition of the EGR valve
connector, ECM connector and coupling connector.


ECM and EGR position sensor using breaker
box or DMM.
cedure, DTC: P0487 (Flash code 44) EGR
position sensor fault, List of Diagnostic Trouble
Codes”.
Note:
3 P0487 (Flash code 44) EGR position sensor fault, —
• Short circuit to EGR position sensor
ground circuit
• Open circuit
• High resistance


2. Clear the DTC.
clear DTCs.
seconds, and then start the engine.
temperature exceeds 80°C (176°F).
5. Check the DTC.
Go to “Diagnostic
Replace the EGR valve (EGR position sensor).
Note:
service manual.

2. Clear the DTC.
clear DTCs.
5. Check the DTC.

necessary.
Note:
8 —

Replace the ECM.
Note:


2. Clear the DTC.
clear DTCs.
seconds.
5. Check the DTC.

About EGR position sensor
TSWG0158
Name
1. Position sensor power supply (5 V)
2. Position sensor signal W
3. Position sensor signal V
4. Position sensor signal U
5. Position sensor ground
6. Motor drive W
7. Motor drive V
8. Motor drive U
Name
1. Breaker box
2. DMM

ground circuit/ measurement EGR valve con- 93 – 101 more
ground nector. 94 – 101
93 – Ground
94 – Ground
Open circuit/ Resistance • Disconnect the 92 – EGR valve con- 100Ω or less 10 MΩ or
high resistance measurement EGR valve connector position sensor more
nector. signal W terminal
• Key switch “OFF” 93 – EGR valve con-
nector position sensor
signal V terminal
94 – EGR valve con-
nector position sensor
signal U terminal
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0488 (Flash code 45) EGR valve control fault
Engine control
module (ECM)
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR valve
TSHK0028

The EGR motor is installed inside the EGR valve. The Exhaust gas is affected.
EGR motor is the brushless DC motor, and is driven by
three phases. The EGR position sensor includes fol- Preconditions when DTC is set
lowing circuits.
• DTC P1630, P1635, P0487, P0488, or P1635 is
• EGR motor drive circuit U not detected.
• EGR motor drive circuit V • Main relay input power supply voltage is higher
• EGR motor drive circuit W than 20 V but lower than 32 V.
The ECM drives the EGR motor through the EGR
motor drive circuits U, V, and W. The ECM outputs DTC set condition
drive signals by the switching inside the ECM, and the • Difference between target valve lift and actual
motor rotates with the combination of three-phase sig- position is more than 20% for 10 seconds or more.
nals. Also, the valve opening angle is controlled by
duty.
The ECM sets the DTC when the EGR motor drive duty
is high and the difference between the target EGR posi- • Trouble is displayed on the monitor of the
tion and actual EGR position is large. machine or diagnosis lamp comes on.
Back-up mode • Defective harness routing
• Instruction to fully close EGR valve • Worn harness cladding
Recovery from failure Following inspections are necessary to detect these
Refer to 1E-284, “List of Diagnostic Trouble Codes” causes.
and “About recovery from failure” in this section for • Improper connection of harness connector and
recovery from failure. ECM connector
• Damaged harness
to history trouble and the key switch is turned – Visually check the harness for damage.
“OFF” then “ON” again. – Check the relevant items on the scan tool data
• Using the scan tool, or memory clear switch and display while moving the connector and the har-
diagnostic switch operation enables to clear DTCs. ness which are related to the sensor. The varia-
Diagnostic aid
Test description
be the cause. Numbers below indicate step numbers in the chart.
5. Check all the EGR motor drive circuits U, V, and W.

1. Perform “EGR control test” using scan tool.
2. Press the “Up” “Down” soft key.
3 3. Check the value for “EGR position”. ±3%
Is “EGR position” within the specified value? Go to Step 4. Go to Step 5.

1. Clear the DTC.
clear DTCs.
4. Check the DTC.
Go to “Diagnostic

1. Check for followings in the motor drive circuit
between ECM and EGR motor using breaker
box or DMM.
cedure, DTC: P0488 (Flash code 45) EGR
valve control fault, List of Diagnostic Trouble
Codes”.
Note:
5 P0488 (Flash code 45) EGR valve control fault, List —
• Open circuit
• High resistance

Note:
service manual.

2. Clear the DTC.
clear DTCs.
5. Check the DTC.

necessary.
Note:
9 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
5. Check the DTC.

1. Remove the EGR valve.
2. Check the EGR valve for anchoring, clogging,
13 etc. —
About EGR valve Name

1. Position sensor power supply (5 V)
2. Position sensor signal W
3. Position sensor signal V
4. Position sensor signal U
5. Position sensor ground
6. Motor drive W
7. Motor drive V
8. Motor drive U
TSWG0158
EGR valve check Breaker box inspection procedure
TSWG0150
Push the EGR valve with finger to make sure it opens/

completely when the finger is released. Name
1. Breaker box
2. DMM

power supply surement EGR valve con- 103 – Ground
circuit nector. 110 – Ground
• Key switch “ON”
ground measurement EGR valve con- 103 – Ground more
nector. 110 – Ground
Open circuit/ Resistance • Disconnect the 111 – EGR valve con- 100Ω or less 10 MΩ or
high resistance measurement EGR valve connector motor drive U more
nector. terminal
• Key switch “OFF” 103 – EGR valve con-
nector motor drive V
terminal
110 – EGR valve con-
nector motor drive W
terminal
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0522 (Flash code 294) Engine oil pressure sensor fault (low voltage fault, open
circuit, ground short)

5V

108 E-56 107 E-56 106 E-56 19 E-57 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
3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
2 E-98 1 E-98
Engine
coolant
temperature
pressure sensor
CKP sensor
A
Engine control
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
TSHK0030

The engine oil pressure sensor detects the engine oil Operationality is not affected.
pressure. The engine oil pressure sensor is installed
near the starter motor of the cylinder block. The resis- Preconditions when DTC is set
tance value in the engine oil pressure sensor changes
according to the pressure. If the pressure is high, the
resistance becomes low; if the pressure is low, the • DTC P1633 is not detected.
resistance becomes high.
The engine control module (ECM) is connected to the DTC set condition
engine pressure sensor via power supply circuit, signal • Engine oil pressure sensor voltage is 0.098V or
circuit and ground circuit, and energizes +5 V power less for 4 seconds or more.
supply to the power supply circuit. The ECM detects
the signal voltage change in response to the change in Action taken when DTC is set
resistance according to the engine pressure sensor
pressure (If the pressure is high, the voltage becomes
high; if the pressure is low, the voltage becomes low)
as a signal.
causes.
• No back-up action
• Damaged harness
be the cause. 3. In case of present trouble, the “Engine oil pressure
• Improper connection of harness connector sensor” displays more than the specified value. In this
• Defective harness routing case, identify the cause by referring to “Diagnostic aid”.
• Worn harness cladding 5. If the “Engine oil pressure sensor” displays more
than the specified value when the ECT sensor connec-
tor is removed, the circuit beyond the sensor is normal
including ECM.

Check the value for engine oil pressure sensor
using scan tool.
3 0.1V
3. Check the value for “Engine oil pressure sen-
Is the “Engine oil pressure sensor” less than the Go to “Diagnostic

Check for installation condition of the engine oil
required.

2. Disconnect the engine oil pressure sensor
connector.
5 0V
Is the “Engine oil pressure sensor” more than the


between ECM and engine oil pressure sensor
oil pressure sensor fault (low voltage fault,
open circuit, ground short), List of Diagnostic
Trouble Codes”.
Note:
P0522 (Flash code 294) Engine oil pressure sensor
fault (low voltage fault, open circuit, ground short),
• Short circuit to engine oil pressure sensor
ground circuit
required.

Replace the engine oil pressure sensor.
7 —
necessary.
Note:
9 —

Replace the ECM.
Note:


2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

2. Check the display of engine oil pressure. 1016 kPa
12 (147.4 psi)
Does the display of engine oil pressure show error (error value) Go to “Diagnostic
required.

oil pressure sensor fault (low voltage fault,
open circuit, ground short), List of Diagnostic
Trouble Codes”.
Note:
fault (low voltage fault, open circuit, ground short),
• Short circuit to engine oil pressure sensor
ground circuit
required.

About engine oil pressure sensor
(V)
4.85
1 2 3
0.496
0 1088.5(157.9)
kPa(psi)
TSWG0202
TSWG0164
Name
Characteristics of engine oil pressure sensor

The output voltage of engine oil pressure sensor
changes according to the engine oil pressure. The scan
tool with CAN communication displays a fixed value
when the value exceeds the threshold voltage. There-
fore, judge as it is more than the threshold value if the
value of 0 kPa (0 psi) or 1088.5 kPa (157.9 psi) is not
changed.
When error occurs, error value (1016 kPa {147.4 psi})
is displayed.
Name
1. Breaker box
2. DMM

ground • Key switch “OFF” 80 – 79
80 – Ground
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0523 (Flash code 295) Engine oil pressure sensor fault (high voltage fault, short to
power supply, ground short)

5V

108 E-56 107 E-56 106 E-56 19 E-57 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
3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
2 E-98 1 E-98
Engine
coolant
temperature
pressure sensor
CKP sensor
A
Engine control
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
TSHK0030

The engine oil pressure sensor detects the engine oil Operationality is not affected.
pressure. The engine oil pressure sensor is installed
near the starter motor of the cylinder block. The resis- Preconditions when DTC is set
tance value in the engine oil pressure sensor changes
according to the pressure. If the pressure is high, the
resistance becomes low; if the pressure is low, the • DTC P1633 is not detected.
resistance becomes high.
The engine control module (ECM) is connected to the DTC set condition
engine pressure sensor via power supply circuit, signal • Engine oil pressure sensor voltage is 4.85V or
circuit and ground circuit, and energizes +5 V power more for 4 seconds or more.
supply to the power supply circuit. The ECM detects
the signal voltage change in response to the change in Action taken when DTC is set
resistance according to the engine pressure sensor
pressure (If the pressure is high, the voltage becomes
high; if the pressure is low, the voltage becomes low)
as a signal.
causes.
• Damaged harness
be the cause. 3. In case of present trouble, the “Engine oil pressure
• Improper connection of harness connector sensor” displays more than the specified value. In this
• Defective harness routing case, identify the cause by referring to “Diagnostic aid”.
• Worn harness cladding 5. If the “Engine oil pressure sensor” displays less than
the specified value when terminals between the engine
oil pressure sensor connector are shorted, the circuit
beyond the sensor is normal including ECM.

Check the value for engine oil pressure sensor
using scan tool.
3 4.85V
Is the “Engine oil pressure sensor” more than the Go to “Diagnostic

required.


connector.
3. Short the engine oil pressure sensor connector
signal terminal to the ground terminal using
5 jump cable. 0V
Is the “Engine oil pressure sensor” less than the

engine oil pressure sensor for short circuit to
ply circuit, using breaker box or DMM.
oil pressure sensor fault (high voltage fault,
short to power supply, ground short), List of
Note:
6 —
fault (high voltage fault, short to power supply,
ground short), List of Diagnostic Trouble Codes”.
Important:
If the engine oil pressure sensor circuit is
may be broken.

Note:
• Open circuit
• High resistance
required.


between ECM and engine oil pressure sensor,
Note:
• Open circuit
• High resistance
required.

Replace the engine oil pressure sensor.
9 —
necessary.
Note:
11 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.


2. Check the display of engine oil pressure. 1016 kPa
15 (147.4 psi)
Does the display of engine oil pressure show error (error value) Go to “Diagnostic
engine oil pressure sensor for short circuit to
Note:
Important:
If the engine oil pressure sensor circuit is
may be broken.

Note:
• Open circuit
• High resistance
required.


between ECM and engine oil pressure sensor,
Note:
• Open circuit
• High resistance
required.
About engine oil pressure sensor The following illustration shows the correlation between
(V)
4.85
1 2 3
0.496
TSWG0164
Name
1. Sensor ground 0 1088.5(157.9)
kPa(psi)
2. Sensor signal
TSWG0202
Characteristics of engine oil pressure sensor

The output voltage of engine oil pressure sensor
changes according to the engine oil pressure. The scan
value of 0 kPa (0 psi) or 1088.5 kPa (157.9 psi) is not
changed.
When error occurs, error value (1016 kPa {147.4 psi})
is displayed.
Name
1. Breaker box
2. DMM


3
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
TSWG0197
DTC: P0601 (Flash code 53) ROM fault
Description of circuit Back-up mode
The internal part of the ECM consists of ROM, • Engine stopped
EEPROM, CPU, and Sub-CPU, which perform data
storage, data clear and various controls. Recovery from failure
The ECM sets the DTC when the ROM fault inside the
ECM is detected.
Engine stopped The conditions to clear the MIL/DTC
DTC set condition the condition is out of the range from DTC set con-
• ROM fault is detected. dition (recovery from failure).
• Reflash failure • The diagnosis lamp will go off after the code turns
Action taken when DTC is set “OFF” then “ON” again.
• Trouble is displayed on the monitor of the • Using the scan tool, or memory clear switch and
machine or diagnosis lamp comes on. diagnostic switch operation enables to clear DTCs.

1. Clear the DTC.
clear DTCs.
seconds.
set”.
4. Check the DTC.
Go to “Diagnostic
necessary.
Note:
4 —


Replace the ECM.
Note:

DTC: P0603 (Flash code 54) EEPROM fault
The internal part of the ECM consists of ROM, • No back-up action
EEPROM, CPU, and Sub-CPU, which perform data
storage, data clear and various controls. Recovery from failure
The ECM sets the DTC when the EEPROM fault inside
the ECM is detected.
Operationality is not affected. The conditions to clear the MIL/DTC
• EEPROM fault is detected. dition (recovery from failure).
Action taken when DTC is set to history trouble and the key switch is turned
• Trouble is displayed on the monitor of the “OFF” then “ON” again.
machine or diagnosis lamp comes on. • Using the scan tool, or memory clear switch and

1. Clear the DTC.
clear DTCs.

seconds.
set”.
4. Check the DTC.
Go to “Diagnostic
necessary.
Note:
4 —

Replace the ECM.
Note:


DTC: P0606 (Flash code 51) CPU fault
The internal part of the ECM consists of ROM, • Limited injection amount 2 (multi-injection stopped)
EEPROM, CPU, and Sub-CPU, which perform data • SUB-CPU stops CPU.
storage, data clear and various controls.
The ECM sets the DTC when the CPU fault or Sub- Recovery from failure
CPU fault inside the ECM is detected.
Main trouble symptom and “About recovery from failure” in this section for
• Output lowering
• Unable to start The conditions to clear the MIL/DTC
• Sub-CPU detects main CPU fault in 100 msec dition (recovery from failure).
after key switch ON. • The diagnosis lamp will go off after the code turns
Action taken when DTC is set “OFF” then “ON” again.
• Trouble is displayed on the monitor of the • Using the scan tool, or memory clear switch and
machine or diagnosis lamp comes on. diagnostic switch operation enables to clear DTCs.

1. Clear the DTC.
clear DTCs.
seconds.
set”.
4. Check the DTC.
Go to “Diagnostic
necessary.
Note:
4 —


Replace the ECM.
Note:

DTC: P0606 (Flash code 52) CPU monitoring IC fault
Description of circuit Action taken when DTC is set
The internal part of the ECM consists of ROM, • Trouble is displayed on the monitor of the
EEPROM, CPU, and Sub-CPU, which perform data machine or diagnosis lamp comes on.
storage, data clear and various controls.
The ECM sets the DTC when the CPU fault or Sub-
CPU fault inside the ECM is detected.
Back-up mode
Main trouble symptom • Limited injection amount 1
• Output lowering
• 480 msec or more has elapsed after key switch and “About recovery from failure” in this section for
ON. recovery from failure.
• Key switch input power supply voltage is higher
than 16 V. The conditions to clear the MIL/DTC
• RUN-SUB pulse does not change for 20 msec or dition (recovery from failure).
more. • The diagnosis lamp will go off after the code turns

1. Clear the DTC.
clear DTCs.

seconds.
set”.
4. Check the DTC.
Go to “Diagnostic
necessary.
Note:
4 —


Replace the ECM.
Note:

DTC: P0611 (Flash code 34) Charge circuit fault (bank 1)
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150
DLC Machine
control unit
5 FL-150 4 FL-150
CAN HIGH CAN LOW
TSHK0023

The charge circuit inside the ECM is the voltage pres- • Main relay power supply voltage is 18V or more.
surizing circuit to apply voltage to the injector, and is
divided in to two systems (4H: 2 cylinders each, 6H: 3 DTC set condition
cylinders each). The charge circuit 1 supplies the
• When charge circuit bank 1 voltage inside ECU is
power supply voltage to the injectors (4H: No. 1, 2 cyl-
low for 1.5 seconds or more.
inders, 6H: No. 1, 2, 3 cylinders). The ECM sets the
DTC when the voltage in the charge circuit 1 is exces-
sively high or excessively low.
• Rough idling
• Output lowering Back-up mode
• Engine blow up fault • Common 1 stop (#1, #4 cylinders stopped), EGR
• Engine stall possible stopped (4HK1)
• Common 1 stop (#1, #2, #3 cylinders stopped),
EGR stopped (6HK1)
Recovery from failure • The diagnosis lamp will go off after the code turns
recovery from failure. • Using the scan tool, or memory clear switch and

1. Make sure all the communication between
ECU and scan tool is normal.
2. Make sure the system which require program-
3 ming operates normally. —
3. Check the DTC.

between ECM terminals (1, 3, 4, 43, 62, 81)
and ECM ground terminal (E2) using breaker
box or DMM.
4 • Open circuit —
• High resistance

2. Remove the ECM ground terminal (E2).
3. Check the ECM ground terminal (E2) for inter-
5 mittent trouble or poor contact. —

2. Remove the ECM.
3. Check the ECM terminals (1, 3, 4, 43, 62, 81)
6 for intermittent trouble or poor contact. —

necessary.
Note:
8 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

12 Is DTC P0611 detected? — Go to Step 4. Go to Step 10.
DTC: P0612 (Flash code 34) Charge circuit fault (bank 2)
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150
DLC Machine
control unit
5 FL-150 4 FL-150
CAN HIGH CAN LOW
TSHK0023

The charge circuit inside the ECM is the voltage pres- • Main relay power supply voltage is 18V or more.
surizing circuit to apply voltage to the injector, and is
divided in to two systems (4H: 2 cylinders each, 6H: 3 DTC set condition
cylinders each). The charge circuit 2 supplies the
• When ECU charge circuit bank 2 voltage is low for
power supply voltage to the injectors (4H: No. 3, 4 cyl-
1.5 seconds or more.
inders, 6H: No. 4, 5, 6 cylinders). The ECM sets the
DTC when the voltage in the charge circuit 2 is exces-
sively high or excessively low.
• Rough idling
• Output lowering Back-up mode
• Engine blow up fault • Common 2 stopped (#2, #3 cylinders stopped),
• Engine stall possible EGR stopped (4HK1)
• Common 2 stopped (#4, #5, #6 cylinders stopped),
EGR stopped (6HK1)

1. Make sure all the communication between
ECU and scan tool is normal.
2. Make sure the system which require program-
3 ming operates normally. —
3. Check the DTC.

between ECM terminals (1, 3, 4, 43, 62, 81)
and ECM ground terminal (E2) using breaker
box or DMM.
4 • Open circuit —
• High resistance

2. Remove the ECM ground terminal (E2).
3. Check the ECM ground terminal (E2) for inter-
5 mittent trouble or poor contact. —

2. Remove the ECM.
3. Check the ECM terminals (1, 3, 4, 43, 62, 81)
6 for intermittent trouble or poor contact. —

necessary.
Note:
8 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

12 Is DTC P0612 detected? — Go to Step 4. Go to Step 10.
DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault
(15A)*
A A
Meter
Tachometer
Boost
3 H-6
1 E-164
Machine
CAN LOW CAN HIGH

Generator
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 8 E-57

Engine control
module (ECM)
Engine oil
Tachometer signal
CAN HIGH CAN LOW
TSHK0022

The power supply voltage is supplied to the diagnosis • Key switch input voltage is 18V or more.
lamp via key switch, and the signal from ECM will turn • DTC P0650 is not detected.
the lamp on. The ECM turns the diagnosis lamp on dur-
ing lamp check with the key switch “ON” and when DTC set condition
DTC is detected. Also when the diagnosis connector is
connected, it blinks the diagnosis lamp according to the • No diagnosis lamp monitor signal exists for 1.5
DTC detected. A monitor circuit is provided inside the seconds or more.
ECM to monitor the lamp operation.
The ECM sets the DTC when the output to the diagno- Back-up mode
sis lamp does not match with the check engine lamp • No back-up action
operation.
Main trouble symptom Refer to 1E-284, “List of Diagnostic Trouble Codes”
Operationality is not affected. and “About recovery from failure” in this section for
dition (recovery from failure). • Damaged harness
• The diagnosis lamp will go off after the code turns – Visually check the harness for damage.

be the cause. 2. If the lamp does not come on with the key switch
• Improper connection of harness connector “ON”, open circuit, short circuit to the ground circuit,
• Defective harness routing blown light bulb, or ECM fault is suspected.
2. If the lamp does not go OFF, short circuit to the
ground circuit, meter circuit fault, or ECM fault is sus-
• Wire disconnection inside harness cladding pected.
Following inspections are necessary to detect these 4. If the lamp goes off when the ECM connector is
causes. removed, the circuit beyond the ECM is normal includ-
• Improper connection of harness connector and ing meter.
ECM connector 7. If the lamp comes on when the lamp control terminal
– Poor connection of terminal from connector is shorted to the ground, the circuit beyond the ECM is
normal including meter.

2 2. Check if the diagnosis lamp is ON. —
Does the diagnosis lamp come on? Go to Step 3. Go to Step 7.
Turn the key switch “ON” and wait for 30 seconds. Go to “Diagnostic
3 —
Does the diagnosis lamp go OFF? aid”. Go to Step 4.
4. Check if the diagnosis lamp is ON.
Does the diagnosis lamp go OFF? Go to Step 12. Go to Step 5.




1. Check the circuit between diagnosis lamp and
ECM for ground short circuit using breaker box
or DMM.
cedure, DTC: P0650 (Flash code 77) Diagno-
sis lamp circuit fault, List of Diagnostic Trouble
Codes”.
6 Note: —
P0650 (Flash code 77) Diagnosis lamp circuit fault,

3. Short between the diagnosis lamp control ter-
minal of the ECM and the ground using
breaker box or DMM.
Codes”.
7 —
Note:
5. Check if the diagnosis lamp is ON.
Does the diagnosis lamp come on? Go to Step 13. Go to Step 8.



fuse and the diagnosis lamp.
• Open circuit
• High resistance


diagnosis lamp and ECM using breaker box or
DMM.
Codes”.
Note:
• Open circuit
• High resistance

Replace the meter.
11 —
Replace the diagnosis lamp bulb.
12 —
necessary.
Note:
14 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.


Check if DTC is detected. (DTC for entire engine
control) Go to the related
17 — “Inspection method
Is DTC detected? by DTC”. Verify repair.

Name
1. Breaker box
2. DMM

6 Short circuit to Resistance • Remove the meter 6 – Ground 10 MΩ or 100Ω or less
ground measurement connector. more
7 Open circuit/ Lamp ON • Remove the ECM. Short the terminal No. Lamp ON Lamp OFF
high resistance • Key switch “ON” 6 with ground circuit.
10 Open circuit/ Resistance • Remove the meter 6 – Meter connector 100Ω or less 10 MΩ or
high resistance measurement connector. diagnosis lamp termi- more
• Key switch “OFF” nal
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1093 (Flash code 227) No pump pressure feed
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
4. Pre-filter
Engine control
module (ECM)
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR valve
TSHK0028
Description of circuit • Black smoke emitted

The supply pump sucks fuel from the fuel tank using • Engine stall
the trochoid-type feed pump located inside of the sup- • Excessive output is possible.
ply pump. The sucked fuel is sent through the SCV to
the two plungers located inside the supply pump, and is
pressurized and sent to the common rail. The SCV
opening angle controls the fuel flow; if the SCV drive
duty is large, the SCV opening angle becomes small
resulting in less fuel flow. The ECM drives the SCV by
calculating the target common rail pressure, target fuel
flow, etc. based on the information from each sensor.
The ECM sets the DTC when the SCV drive duty, or
the target fuel flow and target common rail pressure
exceed certain amount.

• Rough idling
• Output lowering
Fuel system filter
:Desired rail pressure

4
3 :Actual rail pressure
Absolute pressure
5
30MPa(4351psi)
Actual 1 P1093
2
t2 > 5sec
t1 > 3sec
15MPa Actual 2
(2176psi) P0087
TSHK0130
1
TSHK0039
Name
1. Fuel pump strainer • Trouble is displayed on the monitor of the
2. Pre-fuel Filter machine or diagnosis lamp comes on.
3. Electromagnetic pump filter
4. Main fuel filter
5. Gauze filter
Back-up mode
Filter clogging in the fuel system may establish the • Limited injection amount 3 (multi-injection stopped)
DTC set condition. Check as required. • Target RP upper limit (80 MPa {11603 psi})
Preconditions when DTC is set Recovery from failure

• Key switch input voltage is 18V or more. Refer to 1E-284, “List of Diagnostic Trouble Codes”
• DTC P0192, P0193, P1093, P0090, P1291, P1292 and “About recovery from failure” in this section for
or P1635 is not detected. recovery from failure.
• Duty to SCV is 33% or less, or pressure feed is
28000 mm3/sec (1.7 cu⋅in/sec) or more.
• 1200 rpm or more • The present trouble turns to history trouble when
DTC set condition dition (recovery from failure).
Actual rail pressure is 50 MPa (7252 psi) or more lower
than target rail pressure for 5 seconds or more.
Diagnostic aid
Followings are suspected as the cause.
• Injector internal trouble
• Supply pump internal trouble
• Fuel system pipe fault (fuel leakage, clogging,
crush, etc.)
• Fuel filter fault (clogging)
• Fuel tank fault (clogging)
• Pressure limiter trouble (operation under specified
pressure, degradation of sealability)
• ECM trouble
• Common rail pressure sensor trouble 4. When rise of fuel level or diesel fuel odor is con-
firmed, fuel leakage in the injector portion may be the
Test description cause of the DTC detection.
10. If the “Common rail pressure sensor” displays more
than the specified value when the common rail pres-

Check the clogging in the following procedure.
• Fuel filter (main fuel filter, pre-fuel filter,
gauze filter)
2 • Fuel tank (pump strainer) —
• Fuel system pipe
fuel tank for freeze or waxing. (at cold temper-
ature)

Check the electromagnetic pump.
1. Inspect the electromagnetic pump by referring
to 1E-535, “Electromagnetic pump inspection
procedure, DTC: P1093 (Flash code 227) No
3 pump pressure feed, List of Diagnostic Trouble —
Codes”.
2. Repair or replace the faulty part.

Check for rise of fuel level in the oil level gauge or
4 light oil odor. —
Check the connection of the fuel pipe in each injec-
tor, and replace the injector if oil leakage is con-
firmed.
5 Note: —
service manual.


Check the injector.
1. Clear the DTC.
clear DTCs.
7 the menu. —

1. Replace the injector in the cylinder of which
engine sound did not change when it is
stopped in step 9.
8 Note: —
service manual.

display using scan tool.
At engine
3. Start the engine and run it at idle. stopped: −30
4. Check for “Common rail pressure” on the data MPa (−4351
9
display using scan tool. psi); At idling,
5. Race it quickly for about 5 times. racing: ±5 MPa
(±725 psi)
Is each value of “Common rail pressure” (at engine

stopped, idling and racing) around specified value? Go to Step 16. Go to Step 10.
connector.
10 4.8V
Is the “Common rail pressure sensor” more than


box or DMM.
cedure, DTC: P1093 (Flash code 227) No
pump pressure feed, List of Diagnostic Trouble
Codes”.
11 —
Note:
P1093 (Flash code 227) No pump pressure feed,

necessary.
Note:
13 —

Replace the ECM.
Note:

sensor).
Note:
service manual.

1. Clear the DTC.
clear DTCs.
the menu. ±5 MPa (±725
16
psi)
mon rail system”.
“Common rail pressure”.
Is “Common rail pressure” within the specified


Note:
service manual.

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

Check the injector using injector checker.
Refer to 1E-82, “How to use injector checker, How
to Inspect Injector” in this section for how to use
20 injector checker. —


sensor
(V)
4.2
3 2 1
1
0 200(29008)
TSWG0055 MPa(psi)
Name TSWG0201
1. Sensor ground
2. Sensor signal Electromagnetic pump inspection procedure
3. Sensor power supply 1. Turn the key switch to ON, and check for pulsation
in the fuel hose.
• It is normal if pulsation exists.
2. Disconnect the electromagnetic pump connector,
and connect 24V power supply to the electromag-
netic pump side to check if the pump operates.
• If it operates properly, there may be open cir- 2
cuit, short circuit or poor contact in the
machine-side harness. Repair the faulty part,
and check again from Step 1.
• If the electromagnetic pump does not operate,
replace the pump.
1
2
TSHK0107
Name
1. Fuel inlet port
2. Fuel outlet port
3 4. Install the removed parts, and check again from

Step 1.

TSHK0106 Perform the inspection in the following procedure if
Name there is such an instruction to use breaker box in the
1. Electromagnetic pump step. After inspection, return to the diagnostic step.
2. + terminal
3. - terminal
3. Blow air into the inlet of the electromagnetic pump

with your mouth.
• The internal seal may be stuck. Blow air to elim-
inate sticking.
Name
1. Breaker box
2. DMM

2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1095 (Flash code 225) Pressure limiter open
2 4HK1
3
1
6
7
5 6HK1
TSHK0041
Name
4. Pre-filter
Engine control
module (ECM)
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR valve
TSHK0028
The supply pump sucks fuel from the fuel tank using
the trochoid-type feed pump located inside of the sup-
ply pump. The sucked fuel is sent through the SCV to
the two plungers located inside the supply pump, and is
pressurized and sent to the common rail. The SCV
opening angle controls the fuel flow; if the SCV drive
duty is large, the SCV opening angle becomes small
resulting in less fuel flow. The ECM drives the SCV by
calculating the target common rail pressure, target fuel
flow, etc. based on the information from each sensor.
The ECM sets the DTC when the common rail pressure
increases to certain level then lowers sharply, as it rec-
ognizes that the pressure limiter is activated.

• Output lowering
• Hunting
Fuel system filter
4
3
Common rail
pressure
T>1sec=P1095
200 MPa
5 (29008psi)
190 MPa T
(27557psi)
185 MPa
(26832psi)
2
T
T>5sec=P0088
TSHK0043
1
TSHK0039
Name
1. Fuel pump strainer • Trouble is displayed on the monitor of the
2. Pre-fuel filter machine or diagnosis lamp comes on.
3. Electromagnetic pump filter
4. Main fuel filter
5. Gauze filter
Back-up mode
Filter clogging in the fuel system may establish the • Limited injection amount 1
DTC set condition. Check as required. • Output goes down to about 50% since fuel flow is
limited.
• Key switch input voltage is 18V or more. Recovery from failure
• DTC P1095, P0192, P0193, P1630, or P1635 is Refer to 1E-284, “List of Diagnostic Trouble Codes”
not detected. and “About recovery from failure” in this section for
• 50 rpm or more
DTC set condition
• When pressure limiter is opened.
• When common rail pressure is more than 200 MPa dition (recovery from failure).
(29008 psi) for 1 second or more.
• DTC set condition in the case of high common rail to history trouble and the key switch is turned
pressure is described below. Only P1095 is “OFF” then “ON” again.
detected if the fuel pressure overshoots due to
entry of air.
Diagnostic aid
Followings are suspected as the cause.
• Air mixed in the high-pressure fuel pipe.
• Injector internal trouble
• Supply pump internal trouble
• Fuel system pipe fault (clogging etc.)
• Fuel filter fault (temporary clogging due to waxing
at low temperatures, improper tightening of filter
cartridge, etc.)
• Fuel tank fault (temporary clogging, air mixed due • Running out of fuel
to fuel shortage, air mixed due to modified fuel
pipe for additional tank etc.) Test description
• Pressure limiter trouble (operation under specified Numbers below indicate step numbers in the chart.
pressure, degradation of sealability) 8. If the “Common rail pressure sensor” displays more
• ECM trouble than the specified value when the common rail pres-
• Common rail pressure sensor trouble sure sensor connector is removed, the circuit beyond

1. Check and record the DTC.
2. Clear the DTC.
clear DTCs.
3. Check the fuel amount, and add fuel as
required. If fuel is low, P1095 may be detected
due to entry of air.
• If air bleeding is insufficient, overshoot
2 —
exceeds 200 MPa (29008 psi) and DTC will
be detected.
Note:
• Bleeding air from fuel must be performed cor-
rectly, following the procedure.
• For work procedure, refer to “Engine section” in
the service manual.
5. Race it quickly for about 5 times.
6. Check the DTC. Refer to “Diagnostic
aid” and Go to Step
Is DTC P1095 detected? Go to Step 3. 4.
Narrow down the cause.
1. Clear the DTC.
clear DTCs.
2. Connect another pipe to the supply pump inlet
3 duct, and test run while supplying fuel. (At this —
time, replace the fuel hose with a transparent
hose to visually check for air mixture in the
fuel.)
3. Check the DTC.


gauze filter)
4 • Fuel tank (pump strainer) —
ature)

5 —
3. Start the engine and run it at idle. At engine
stopped: −30
MPa (−4351
7 data display using scan tool.
psi); At idling,
5. Race it quickly for about 5 times. racing: ±5 MPa
6. Check for “Differential fuel rail pressure” on the (±725 psi)
Is each value of “Fuel rail pressure” (at engine

stopped, idling and racing) around the specified
connector.
8 0V
Is the “Common rail pressure sensor” specified


box or DMM.
cedure, DTC: P1095 (Flash code 225) Pres-
sure limiter open, List of Diagnostic Trouble
Codes”.
9 —
Note:
P1095 (Flash code 225) Pressure limiter open, List

necessary.
Note:
11 —

Replace the ECM.
Note:

sensor).
Note:
service manual.

1. Restore the machine.
3. Clear the DTC.
14 of Trouble Diagnosis” in this section for how to —
clear DTCs.
set”.
5. Check the DTC.


1. Replace the common rail.
Note:
service manual.
3. Clear the DTC.
15 Refer to 1E-20, “How to clear DTC, Procedure —
clear DTCs.
set”.
5. Check the DTC.

1. Clear the DTC.
clear DTCs.
If Tech2 is available, go to step 3.
If Tech2 is not available, Go to Step 17.
3. Select the “Boost temperature sensor” from ±5 MPa (±725
16
the menu. psi)
mon rail system”.
“Differential fuel pressure”.
Is “Differential fuel rail pressure” within the speci-

Note:
• Bleed air completely after the parts are
replaced. If air bleeding is not sufficient, P1095
17 may be detected due to overshoot of fuel pres- —
sure.
• For work procedure, refer to “Engine section” in
the service manual.

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.


connector.
pressure sensor connector signal terminal and
20 the ground. 0V
Note:
If the display of DMM is not specified value, ECM
side wiring, wrap-around in ECM or short circuit
may be the cause.
If it is specified value, ECM side wiring is normal.

sensor
(V)
4.2
3 2 1
1
0 200(29008)
TSWG0055 MPa(psi)
Name TSWG0201
1. Sensor ground
2. Sensor signal
Name
1. Breaker box
2. DMM

open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground
short)
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
74 E-56 109 E-56 91 E-56 95 E-56
15 H-20 17 H-20 16 H-20 8 H-20
0.75 0.75 0.75 0.75 0.75

B/R R/L R/L L R/W
2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

TSWG0079

The boost temperature sensor is installed to the intake • Key switch input voltage is 18V or more.
manifold. The resistance value of boost temperature • DTC P1634 is not detected.
sensor changes according to the temperature in intake
manifold. DTC set condition
The resistance is low when the intake air temperature
is high, and is high when the temperature is low. The • Boost temperature sensor voltage is 0.1V or less
ECM energizes 5 V to the boost temperature sensor for 4 seconds or more.
through the pull up resistance, and calculates the boost
temperature from the change in voltage, to utilize vari- Action taken when DTC is set
ous control such as fuel injection control. If the resis- • Trouble is displayed on the monitor of the
tance is low (temperature is high), the voltage becomes machine or diagnosis lamp comes on.
low; if the resistance is high (temperature is low), the
voltage becomes high.

Operationality is not affected. • No back-up action
ECM connector
• The diagnosis lamp will go off after the code turns – Check the relevant items on the scan tool data
to history trouble and the key switch is turned display while moving the connector and the har-
“OFF” then “ON” again. ness which are related to the sensor. The varia-
diagnostic switch operation enables to clear DTCs. Test description
3. In case of present trouble, the “Boost temperature
If the intermittent trouble is suspected, followings may sensor” displays less than the specified value. If more
be the cause. than the specified value, identify the cause by referring
• Improper connection of harness connector to “Diagnostic aid”.
• Defective harness routing 5. If the “Boost temperature sensor” displays more than
• Worn harness cladding the specified value when terminals between the boost
temperature sensor connector are shorted, the circuit
• Wire disconnection inside harness cladding beyond the sensor is normal including ECM.
causes.

2. Check for “Boost temperature sensor” on the
3 data display using scan tool. 0.1V
Is the “Boost temperature sensor” less than the Go to “Diagnostic
Check for installation condition of the boost temper-
ature sensor connector, ECM connector and cou-
pling connector.

2. Disconnect the boost temperature sensor con-
nector.
3. Short between the boost temperature sensor
connector ground terminal and the signal ter-
5 minal using jump cable. 4.8V
5. Check for “Boost temperatureh” on the data
Is the “Boost temperatureh” more than the speci-


between ECM and boost temperature sensor,
ground short), List of Diagnostic Trouble
Codes”.
Note:
P1112 (Flash code 295) Boost temperature sensor
fault (low voltage fault, ground short), List of Diag-
• Open circuit
• High resistance

Codes”.
Note:
7 P1112 (Flash code 295) Boost temperature sensor —
• Short circuit to boost temperature sensor
ground circuit
• Open circuit
• High resistance

Replace the boost temperature sensor.
8 —
necessary.
Note:
10 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

2. Check the display of boost temperature. 214°C (419°F)
14
(error value)
Does the display of “Boost temperatureh” show Go to “Diagnostic
pling connector.

Codes”.
Note:
• Open circuit
• High resistance


Codes”.
Note:
17 P1112 (Flash code 295) Boost temperature sensor —
• Short circuit to boost temperature sensor
ground circuit
• Open circuit
• High resistance
About boost temperature sensor The following illustration shows the correlation between
(V)
4.9824
1.1719
Name
1. Signal -40 120
2. GND (-40) (248) F
TSWG0204
Characteristics of boost temperature sensor

The output voltage of boost temperature sensor
changes according to the boost temperature. The scan
value of −40°C (−40°F) or 120°C (248°F) is not
changed.
played.
1000
100
10
Resistance
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060

Name
1. Breaker box
2. DMM

2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open
circuit, short to power supply circuit)
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
74 E-56 109 E-56 91 E-56 95 E-56
15 H-20 17 H-20 16 H-20 8 H-20
0.75 0.75 0.75 0.75 0.75

B/R R/L R/L L R/W
2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

TSWG0079

The boost temperature sensor is installed to the intake • Key switch input voltage is 18V or more.
manifold. The resistance value of boost temperature • DTC P1634 is not detected.
sensor changes according to the temperature in intake
• Coolant temperature is 50°C (122°F) or more.
manifold.
The resistance is low when the intake air temperature • 3 (or 5) minutes have passed after engine starting
is high, and is high when the temperature is low. The
ECM energizes 5 V to the boost temperature sensor
through the pull up resistance, and calculates the boost DTC set condition
temperature from the change in voltage, to utilize vari- • Boost temperature sensor voltage is 4.941 V or
ous control such as fuel injection control. If the resis- more for 4 seconds or more (4HK1).
tance is low (temperature is high), the voltage becomes • Boost temperature sensor voltage is 4.95 V or
low; if the resistance is high (temperature is low), the more for 4 seconds or more (6HK1).
voltage becomes high.

causes.
Back-up mode
• No back-up action ECM connector
• Damaged harness
• The diagnosis lamp turns off when the trouble tion of the display indicates the faulty part.
code turns to the history trouble.
Test description
diagnostic switch operation enables to clear DTCs. Numbers below indicate step numbers in the chart.
3. In case of present trouble, the “Boost temperature
Diagnostic aid sensor” displays more than the specified value. If less
than the specified value, identify the cause by referring
to “Diagnostic aid”.
be the cause.

2. Check for “Boost temperature sensor” on the
3 data display using scan tool. 4.95V
Is the “Boost temperature sensor” more than the Go to “Diagnostic
pling connector.


boost temperature sensor for short circuit to
open circuit, short to power supply circuit), List
Note:
fault (high voltage fault, open circuit, short to power
supply circuit), List of Diagnostic Trouble Codes”.
Important:
If the boost temperature sensor circuit is
may be broken.

Note:
• Open circuit
• High resistance

Replace the boost temperature sensor.
7 —
necessary.
Note:
9 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

2. Check the display of boost temperature. 214°C (419°F)
13
(error value)
Does the display of “Boost temperatureh” show Go to “Diagnostic
pling connector.

boost temperature sensor for short circuit to
Note:
Important:
If the boost temperature sensor circuit is
may be broken.


Note:
• Open circuit
• High resistance
About boost temperature sensor Tech2 and scan tools with KW communication can dis-
(V)
4.9824
1.1719
-40 120
(-40) (248) F
TSWG0204
Name
1. Signal
2. GND
Characteristics of boost temperature sensor

The output voltage of boost temperature sensor
changes according to the boost temperature. The scan
value of −40°C (−40°F) or 120°C (248°F) is not
changed.
played.
1000
100
10
Resistance
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060

Name
1. Breaker box
2. DMM

6, 16 Open circuit/ Resistance • Disconnect the 109 – Sensor connec- 100Ω or less 10 MΩ or
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1173 (Flash code 542) Overheat

5V

108 E-56 107 E-56 106 E-56 19 E-57 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
3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
2 E-98 1 E-98
Engine
coolant
temperature
pressure sensor
CKP sensor
A
Engine control
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
TSHK0030
The engine coolant temperature (ECT) sensor is
installed in the thermostat housing. The ETC sensor is
the thermistor-type sensor, and the value of resistance
and output voltage change according to the engine
coolant temperature. As the engine coolant tempera-
ture increases, the resistance becomes small, and the 100%
(226 )
voltage lowers. The ECM detects the engine coolant

temperature based on the signal from the ECT sensor
to perform various controls.
Fuel fiow
The ECM sets the DTC when it judges that the engine (248 )
coolant temperature exceed certain level based on the
signal from the ECT sensor.

• Output lowering (221 )
• Fuel flow is regulated during overheat when the
TSWG0169
Preconditions when DTC is set • Using the scan tool, or memory clear switch and
• DTC P1630, P1633, P0117, or P0118 is not Diagnostic aid
detected.
• Engine under operation
be the cause.
DTC set condition • Improper connection of harness connector
• Engine coolant temperature is more than 110°C
(230°F) for 5 seconds or more (4HK1). • Worn harness cladding
• Engine coolant temperature is more than the • Wire disconnection inside harness cladding
threshold value for 5 seconds or more (6HK1). Following inspections are necessary to detect these
causes.
Action taken when DTC is set ECM connector
• Trouble is displayed on the monitor of the – Poor connection of terminal from connector
machine or diagnosis lamp comes on. – Unmatched terminals are fitted.
Back-up mode • Damaged harness
• No back-up action – Visually check the harness for damage.
Recovery from failure display while moving the connector and the har-
Test description
The conditions to clear the MIL/DTC Numbers below indicate step numbers in the chart.
less than the specified value when the ECT sensor
connector is removed, the sensor is faulty.
9. If no DTC is detected, intermittent trouble is sus-
• The diagnosis lamp will go off after the code turns pected. Identify the cause by referring to “Diagnostic
to history trouble and the key switch is turned aid”.

2 2. Check the DTC. —
Go to the relevant
Is DTC P0088, or P1093 detected? DTC detected. Go to Step 3.
4.9V/−40°C (−
4 4. Check for “Engine coolant temperature sen-
40°F)
sor” on the data display using scan tool.
Is the “Engine coolant temperature sensor” more


1. Check the signal circuit between ECT sensor
and ECM for short circuit to signal circuits of
other sensors using breaker box or DMM.
cedure, DTC: P1173 (Flash code 542) Over-
heat, List of Diagnostic Trouble Codes”.
5 Note: —
P1173 (Flash code 542) Overheat, List of Diagnos-

1. Check the engine coolant amount.
2. If insufficient, add engine coolant.
3. Clear the DTC.
6 clear DTCs. —
seconds.
5. Start the engine, and check the DTC.

1. Check for following mechanical defects. (Refer
to “Cooling system” of “Engine section” in the
service manual.)
• Clogging of radiator
• Defective radiator cap
• Loose fan belt
7 • Defective thermostat —
• Defective water pump
• Defective cylinder head gasket
2. If the trouble is detected, adjust or replace as
required.

8 —
1. Clear the DTC.
clear DTCs.

seconds.
set”.
4. Check the DTC.
Go to “Diagnostic

necessary.
Note:
11 —

Replace the ECM.
Note:

14 4. Check the display of the “Engine coolant tem- −40°C (−40°F)
perature”.
Is the “Engine coolant temperature” more than the

About ECT sensor Characteristics of ECT sensor

2 1 CAN communication displays a fixed value when the
40°C (−40°F) or 120°C (248°F) is not changed.
3
1 2 3
TSWG0061
Name
1. Sensor ground (for engine control)
2. Sensor signal (for engine control)
3. Sensor signal (for meter)
(V)
4.7441
0.2129
-40 120
(-40) (248) F
TSWG0181
Name
Breaker box inspection procedure 1. Breaker box
Perform the inspection in the following procedure if 2. DMM
other signal cir- surement sensor connector.
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault
Key switch (ON)
(15A)*
Reguration
29 E-57 41 E-57 33 E-57 47 E-57 30 E-57 31 E-57 49 E-57 50 E-57 51 E-57
ECM
TSHK0143

The idling control switch is provided to adjust idle • When both of idling control up signal and idling
speed during warming-up, and is available for use control down signal are ON.
when the idling control selector switch is in “Manual”.
The power supply voltage is supplied to the idling con- Action taken when DTC is set
trol switch through the key switch. By pressing the “Up” • Trouble is displayed on the monitor of the
or “Down”, each ground circuit is completed and the machine or diagnosis lamp comes on.
signal is input to the ECM.
The ECM sets the DTC when the signal inputs are
detected for idling control switch “Up” side and “Down”
side at the same time.
Back-up mode
Main trouble symptom • Unable to change the speed in mode driving
The conditions to clear the MIL/DTC • Improper connection of harness connector and
ECM connector
the condition is out of the range from DTC set con- – Poor connection of terminal from connector
dition (recovery from failure). – Unmatched terminals are fitted.
• Damaged harness
Diagnostic aid
• Fault in switch body ness which are related to the sensor. The varia-
• Improper adjustment of switch tion of the display indicates the faulty part.
• Defective harness routing Test description
• Worn harness cladding Numbers below indicate step numbers in the chart.
• Wire disconnection inside harness cladding 3. If the “Idle up switch” and “Idle down switch” display
Following inspections are necessary to detect these “OFF” when the idling control switch connector is
causes. removed, the circuit is shorted between idle up circuit
and idle down circuit, or the switch is faulty.

2. Disconnect the idling control switch connector.
3 4. Check for “Idle up switch” and “Idle down —
switch” on the data display using scan tool.
Are the “Idle up switch” and “Idle down switch” dis-

played “OFF”? Go to Step 6. Go to Step 4.
1. Check the idle up-side circuit between idling
control switch and ECM for short circuit to the
cedure, DTC: P1225 (Flash code 31) Idle UP/
DOWN switch fault, List of Diagnostic Trouble
Codes”.
4 —
Note:
P1225 (Flash code 31) Idle UP/DOWN switch fault,


1. Check the idle down-side circuit between idling
control switch and ECM for short circuit to the
cedure, DTC: P1225 (Flash code 31) Idle UP/
DOWN switch fault, List of Diagnostic Trouble
Codes”.
5 —
Note:
P1225 (Flash code 31) Idle UP/DOWN switch fault,

Replace the idling control switch.
6 —
necessary.
Note:
8 —

Replace the ECM.
Note:

2. Clear the DTC.
10 clear DTCs. —
4. Check the DTC.

About idling control switch
Note:
Refer to the machine’s manual for installing position of
the idling control switch.

Name
1. Breaker box
2. DMM

power supply surement switch connector.
power supply surement switch connector.
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness
DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault
4HK1
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

3 3
3 E-35 3 E-37 E-27 E-31
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

B+ B+

TSHK0031
6HK1

2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

No. 5 No. 6 No. 4 No. 2 No. 1 No. 3

B+ B+

TSWG0076

The COMMON circuit is provided to supply the power • Main relay power supply voltage is 18V or more.
supply voltage pressurized in the charge circuit inside • 70 rpm or more
the ECM to the injector, and is divided in to two sys-
• None of the following DTC sets are detected; DTC
tems (4H: 2 cylinders each, 6H: 3 cylinders each). The
P0611, P1261 and P0201; DTC P0611, P1261
COMMON 1 circuit supplies the power supply voltage
and P0204. (4HK1)
to the injectors (4H: No. 1, No. 4 cylinders, 6H: No. 1,
No. 2, No. 3 cylinders). The ECM sets the DTC when • None of the following DTC sets are detected; DTC
faults are detected simultaneously for all the injector P0611, P1261 and P0201; DTC P0611, P1261
drive circuits of COMMON 1 system. and P0202; DTC P0611, P1261 and P0203.
(6HK1)
DTC set condition
• None of injector monitor input signal for COMMON
• Rough idling
1 system exists for 3 seconds or more.
• Output lowering
• Engine stall possible
Action taken when DTC is set • Using the scan tool, or memory clear switch and
Diagnostic aid
be the cause.
Back-up mode • Improper connection of harness connector
Common 1 stop (#1, #4 cylinders stopped), EGR • Defective harness routing
stopped (4HK1) • Worn harness cladding
Common 1 stop (#1, #2, #3 cylinders stopped), EGR
stopped (6HK1)
causes.
Refer to 1E-284, “List of Diagnostic Trouble Codes” ECM connector
The conditions to clear the MIL/DTC – Damage of connector lock
• The present trouble turns to history trouble when – Poor contact between terminal and wire
the condition is out of the range from DTC set con- • Damaged harness
dition (recovery from failure). – Visually check the harness for damage.

2. Remove the ECM-side harness connector
from the coupling connector (H-94).
3. Connect the DMM between the injector power
supply 1 circuit and the ground.
2 7.0V
4H: H94 female-side No. 1

3. Measure the resistance between the injector
3 1.0Ω
harness connector terminals.
4H: H94 male-side No. 1 and No. 4
Check for installation condition of the injector har-
ness connector, ECM connector and coupling con-
nector.


1. Check for followings in the injector power sup-
ply 1 circuit using breaker box or DMM.
cedure, DTC: P1261 (Flash code 158) Injec-
tion nozzle common 1 drive system fault, List
Note:
5 P1261 (Flash code 158) Injection nozzle common 1 —
drive system fault, List of Diagnostic Trouble
Codes”.
• Open circuit
• High resistance

3. Measure the resistance between the No. 1 cyl-
6 10MΩ
inder injector drive circuit and the ground.
4H: H94 male-side No. 5
Is the resistance more than the specified value? Go to Step 7. Go to Step 9.

7 inder (4H: No. 2 cylinder) injector drive circuit 10MΩ
and the ground.
4H: Go to Step 12.
Is the resistance more than the specified value? 6H: Go to Step 8. Go to Step 10.
8 3. Measure the resistance between the No. 3 cyl- 10MΩ

1. Check the No. 1 cylinder injector drive circuit
between ECM and coupling connector (H-94)
for ground short circuit using breaker box or
DMM.
9 Note: —
P1261 (Flash code 158) Injection nozzle common 1
Codes”.

1. Check the No. 2 cylinder (4H: No. 4 cylinder)
injector drive circuit between ECM and cou-
pling connector (H-94) for ground short circuit,
10 Note: —
Codes”.

DMM.
11 Note: —
Codes”.

2. Check for installation condition of the injector
12 harness. —


1. Remove the injector harness from the injector.
4H: No. 1 cylinder, No. 4 cylinder
6H: No. 1 cylinder, No. 2 cylinder, No. 3 cylin-
der
13 10MΩ
2. Measure the resistance between each injector
terminal and the ground.
2. Remove the injector-side harness connector
3. Connect the DMM between the No. 1 cylinder
14 injector drive circuit and the ground. 0V

(4H: No. 4 cylinder) injector drive circuit and
15 the ground. 0V
Is the DMM indication more than the specified 4H: Go to Step 17.
value? Go to Step 19. 6H: Go to Step 16.

supply 1 circuit and the ground.
17 4H: H94 female-side No. 1 7.0V


or DMM.
18 —
Note:
Codes”.

pling connector (H-94) for short circuit to the
circuit, using breaker box or DMM.
19 —
Note:
Codes”.

ignition power supply circuit, using breaker box
or DMM.
20 —
Note:
Codes”.


1. Check the injector power supply 1 circuit
or DMM.
21 —
Note:
Codes”.

Replace the injector harness.
22 —
Replace the injector.
Note:
service manual.

necessary.
Note:
25 —

Replace the ECM.
Note:


2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.


Name
1. Breaker box
2. DMM

5 Open circuit/ Resistance • Remove the ECM- 121 – Female-side ter- 100Ω or less 10 MΩ or
high resistance measurement side harness con- minal more
nector from the (4H: No. 1, 6H: No. 3)
coupling connec-
tor.
Short circuit to Resistance • Remove the ECM- 121 – Ground 10 MΩ or 100Ω or less
ground measurement side harness con- more
nector from the
coupling connec-
tor.

9 Short circuit to Resistance • Remove the ECM- 119 – Ground 10 MΩ or 100Ω or less
nector from the
coupling connec-
tor.
nector from the
coupling connec-
tor.
nector from the
coupling connec-
tor.
18 Short circuit to Voltage mea- • Remove the ECM- 119 – Ground 0V 18V or more
power supply surement side harness con-
circuit nector from the
coupling connec-
tor.
coupling connec-
tor.
coupling connec-
tor.
coupling connec-
tor.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault
4HK1
2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

3 3
3 E-35 3 E-37 E-27 E-31
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94
1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

B+ B+

TSHK0031
6HK1

2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

No. 5 No. 6 No. 4 No. 2 No. 1 No. 3

B+ B+

TSWG0076

The COMMON circuit is provided to supply the power • Main relay power supply voltage is 18V or more.
supply voltage pressurized in the charge circuit inside • 70 rpm or more
the ECM to the injector, and is divided in to two sys-
• None of the following DTC sets are detected; DTC
tems (4H: 2 cylinders each, 6H: 3 cylinders each). The
P0612, P1262 and P202; DTC P0612, P1262 and
COMMON 2 circuit supplies the power supply voltage
P0203. (4HK1)
to the injectors (4H: No. 2, No. 3 cylinders, 6H: No. 4,
No. 5, No. 6 cylinders). The ECM sets the DTC when • None of the following DTC sets are detected; DTC
faults are detected simultaneously for all the injector P0612, P1262 and P204; DTC P0612, P1262 and
drive circuits of COMMON 2 system. P0205; DTC P0612, P1262 and P0206. (6HK1)
Main trouble symptom DTC set condition

• Intense engine vibration • None of injector monitor input signal for COMMON
2 system exists for 3 seconds or more.
• Rough idling
• Output lowering Action taken when DTC is set
• Engine blow up fault • Trouble is displayed on the monitor of the
• Engine stall possible machine or diagnosis lamp comes on.
Back-up mode Diagnostic aid
Common 2 stop (#2, #3 cylinders stopped), EGR If the intermittent trouble is suspected, followings may
stopped (4HK1) be the cause.
Common 2 stop (#4, #5, #6 cylinders stopped), EGR • Improper connection of harness connector
stopped (6HK1)
Recovery from failure • Worn harness cladding
causes.
The conditions to clear the MIL/DTC ECM connector
the condition is out of the range from DTC set con- – Unmatched terminals are fitted.
dition (recovery from failure). – Damage of connector lock
• The diagnosis lamp will go off after the code turns – Poor contact between terminal and wire
to history trouble and the key switch is turned • Damaged harness

2. Disconnect the ECM-side harness connector
from the coupling connector (4H: H-94, 6H: H-
95).
2 supply 2 circuit and the ground. 7.0V

95).
3 3. Measure the resistance between the injector 1.0Ω
harness connector terminals.
Check for installation condition of the injector har-
ness connector, ECM connector and coupling con-
nector.


1. Check for followings in the injector power sup-
ply 2 circuit using breaker box or DMM.
Note:
5 P1262 (Flash code 159) Injection nozzle common 2 —
Codes”.
• Open circuit
• High resistance

95).
6 10MΩ
inder (4H: No. 2 cylinder) injector drive circuit
and the ground.

95).
7 inder (4H: No. 3 cylinder) injector drive circuit 10MΩ
and the ground.
4H: Go to Step 12.
Is the resistance more than the specified value? 6H: Go to Step 8. Go to Step 10.
8 3. Measure the resistance between the No. 6 cyl- 10MΩ

pling connector (4H: H-94, 6H: H-95) for
ground short circuit using breaker box or
DMM.
9 —
Note:
Codes”.

pling connector (4H: H-94, 6H: H-95) for
DMM.
10 —
Note:
Codes”.

DMM.
11 Note: —
Codes”.

2. Check for installation condition of the injector
12 harness. —


1. Remove the injector harness from the injector.
4H: No. 2 cylinder, No. 3 cylinder
6H: No. 4 cylinder, No. 5 cylinder, No. 6 cylin-
der
13 10MΩ
2. Measure the resistance between each injector
terminal and the ground.
95).
14 (4H: No. 2 cylinder) injector drive circuit and 0V
the ground.

95).
(4H: No. 4 cylinder) injector drive circuit and
15 the ground. 0V
Is the DMM indication more than the specified 4H: Go to Step 17.
value? Go to Step 19. 6H: Go to Step 16.

95).
17 supply 2 circuit and the ground. 7.0V


pling connector (4H: H-94, 6H: H-95) for short
circuit to the power supply circuit or ignition
power supply circuit, using breaker box or
DMM.
18 of Diagnostic Trouble Codes”. —
Note:
Codes”.

pling connector (4H: H-94, 6H: H-95) for short
circuit to the power supply circuit or ignition
power supply circuit, using breaker box or
DMM.
19 of Diagnostic Trouble Codes”. —
Note:
Codes”.

or DMM.
20 —
Note:
Codes”.


1. Check the injector power supply 2 circuit
between ECM and coupling connector (4H: H-
94, 6H: H-95) for short circuit to the power sup-
ply circuit or ignition power supply circuit, using
breaker box or DMM.
21 —
Note:
Codes”.

Replace the injector harness.
22 —
Replace the injector.
Note:
service manual.

necessary.
Note:
25 —

Replace the ECM.
Note:


2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.


Name
1. Breaker box
2. DMM

5 Open circuit/ Resistance • Remove the ECM- 116 – Female-side ter- 100Ω or less 10 MΩ or
high resistance measurement side harness con- minal more
nector from the (4H: H94 No.3, 6H:
coupling connec- H95 No.3)
tor.
Short circuit to Resistance • Remove the ECM- 116 – Ground 10 MΩ or 100Ω or less
nector from the
coupling connec-
tor.

nector from the
coupling connec-
tor.
nector from the
coupling connec-
tor.
nector from the
coupling connec-
tor.
coupling connec-
tor.
coupling connec-
tor.
coupling connec-
tor.
coupling connec-
tor.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1271 (Flash code 24) Accelerator sensor 1-2 comparison fault
A A Engine control
module (ECM)
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW

20 H-20 19 H-20 18 H-20

TSHK0029
Description of circuit The ECM sets the DTC when the difference in the
The accelerator position (AP) sensor is installed to the accelerator opening angle is large between which is
accelerator pedal. The AP sensor is the potentiometer- detected based on the AP sensor 1 signal, and which is
type sensor, and the value of output voltage changes detected based on the AP sensor 2 signal.
according to the accelerator opening angle. Two AP
sensors are installed, each of which includes following Main trouble symptom
circuits. 1 system fault: No backup
• 5-V power supply circuit 2 systems fault: Accelerator opening angle is controlled
to 0%.
• Ground circuit
• AP sensor signal circuit Preconditions when DTC is set
The ECM provides 5 V to the AP sensor through 5-V
power supply circuit, and grounds to the inside of the • Key switch input voltage is 18V or more.
ECM through ground circuit. Also, the AP sensor out- • DTC P1630, P1631, P1271, P1277, P1278,
puts the signal voltage to the ECM through AP sensor P1282, or P1283 is not detected.
signal circuit. When the accelerator opening angle is
large, the AP sensor 1 outputs high voltage, whereas DTC set condition
the AP sensor 2 outputs low voltage. Difference in opening angle between accelerator sen-
sors 1 and 2 is 45% or more for 3 seconds or more.
• [Accelerator sensor 1 voltage + Accelerator sensor Diagnostic aid
2 voltage] is higher than 6.4 V.
• [Accelerator sensor 1 voltage + Accelerator sensor be the cause.
2 voltage] is lower than 3.6 V.
Action taken when DTC is set • Defective harness routing
• The diagnosis lamp does not come on.
causes.
• 1 system fault...No back-up
• 2 systems fault... Accelerator opening angle is ECM connector
controlled to 0%.
to history trouble and the key switch is turned Test description
“OFF” then “ON” again. Numbers below indicate step numbers in the chart.
• Using the scan tool, or memory clear switch and 3. Measure at the harness connector-side.

seconds.

3. Check the DTC.
Go to “Diagnostic
2. Disconnect the AP sensor connector.
3. Connect the DMM between the sensor power
supply terminal of the AP sensor connector
3 and the ground. 4.7V


3. Short between the sensor power supply termi-
nal of the AP sensor connector and the signal
terminal using jump cable.
5 4.7V
5. Check for “Accelerator sensor 1” on the data
Is the “Accelerator sensor 1” more than the speci-

1. Check for high resistance in the power supply
circuit between ECM and AP sensor using
breaker box or DMM.
cedure, DTC: P1271 (Flash code 24) Acceler-
ator sensor 1-2 comparison fault, List of
6 Note: —
P1271 (Flash code 24) Accelerator sensor 1-2
comparison fault, List of Diagnostic Trouble
Codes”.

1. Check for high resistance in the signal circuit
between ECM and AP sensor using breaker
box or DMM.
7 Note: —
Codes”.

1. Check for high resistance in the ground circuit
box or DMM.
8 Note: —
Codes”.


1. Check for high resistance in the signal circuit
box or DMM.
9 Note: —
Codes”.

3. Check the AP sensor connector terminal for
10 intermittent trouble or poor contact. —

2. Remove the ECM.
3. Check the ECM terminals (41, 63, 42, 60, 64,
11 61) for intermittent trouble or poor contact. —

Replace the AP sensor.
12 —
necessary.
Note:
14 —

Replace the ECM.
Note:


2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

4. Connect the DMM between the sensor power
18 4.7V
supply terminal of the AP sensor connector
and the signal circuit.

About AP sensor
Refer to the machine’s manual for installing position of
the AP sensor.
Characteristics of AP sensor
(V)
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM

high resistance measurement sensor connector. sensor power supply more

high resistance measurement sensor connector. sensor ground termi- more

high resistance measurement sensor connector. sensor signal terminal more
high resistance measurement sensor connector. sensor signal terminal more
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1277 (Flash code 24) Accelerator sensor 1 fault (low voltage fault)
A A Engine control
module (ECM)
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW

20 H-20 19 H-20 18 H-20

TSHK0029

The accelerator position (AP) sensor is installed to the 1 system fault: No backup
accelerator pedal. The AP sensor is the potentiometer- 2 systems fault: Accelerator opening angle is controlled
type sensor, and the value of output voltage changes to 0%.
according to the accelerator opening angle. The AP
sensor includes following circuits. Preconditions when DTC is set
• 5-V power supply circuit • Key switch input voltage is 18V or more.
• Ground circuit • DTC P1630, P1277, or P1631 is not detected.
• AP sensor signal circuit
The ECM provides 5 V to the AP sensor through 5-V DTC set condition
power supply circuit, and grounds to the inside of the • AP sensor 1 voltage is 0.2V or less for 1 second or
ECM through ground circuit. Also, the AP sensor out- more.
puts the signal voltage to the ECM through AP sensor
signal circuit. The AP sensor 1 outputs high voltage
when the accelerator opening angle is large.
The ECM sets the DTC when the signal voltage from • The diagnosis lamp does not come on.
the AP sensor 1 is less than the normal range.
• 1 system fault...No back-up • Worn harness cladding
• 2 systems fault... Accelerator opening angle is • Wire disconnection inside harness cladding
controlled to 0%. Following inspections are necessary to detect these
causes.
Test description
3. In case of present trouble, the “Accelerator sensor 1”
When the DTC P1282 is detected at the same time, the displays less than the specified value. If more than the
accelerator pedal position sensor and the accelerator specified value, identify the cause by referring to “Diag-
pedal position sensor signal circuit (before the bifurca- nostic aid”.
tion point) may be faulty. 5. If the “Accelerator sensor 1” displays more than the
If the intermittent trouble is suspected, followings may specified value when terminals between the AP sensor
be the cause. connector are shorted, the circuit beyond the sensor is
• Improper connection of harness connector normal including ECM.

3 display using scan tool. 0.2V
Is the “Accelerator sensor 1” less than the specified Go to “Diagnostic
Check for installation condition of the AP sensor


nal of the AP sensor connector and the sensor
1 signal terminal using jump cable.
5 4. Turn the key switch to “ON”. 4.8V



box or DMM.
ator sensor 1 fault (low voltage fault), List of
Note:
P1277 (Flash code 24) Accelerator sensor 1 fault
(low voltage fault), List of Diagnostic Trouble
Codes”.
• Open circuit
• High resistance

box or DMM.
Note:
7 P1277 (Flash code 24) Accelerator sensor 1 fault —
Codes”.
• Short circuit to AP sensor ground circuit
• Open circuit
• High resistance

8 —
necessary.
Note:
10 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

14 display. 0.2V


16 4.8V
display.

About AP sensor Breaker box inspection procedure
Refer to the machine’s manual for installing position of Perform the inspection in the following procedure if
the AP sensor. there is such an instruction to use breaker box in the
(V)
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM

high resistance measurement sensor connector. sensor 1 power sup- more
• Key switch “OFF” ply terminal

high resistance measurement sensor connector. sensor 1 signal termi- more
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1278 (Flash code 24) Accelerator sensor 1 fault (high voltage fault)
A A Engine control
module (ECM)
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW

20 H-20 19 H-20 18 H-20

TSHK0029

power supply circuit, and grounds to the inside of the • AP sensor 1 voltage is 4.9V or more for 1 second
ECM through ground circuit. Also, the AP sensor out- or more.
the AP sensor 1 is more than the normal range.
causes.
Test description
When the DTC P1283 is detected at the same time, the displays more than the specified value. If less than the
accelerator pedal position sensor and accelerator specified value, identify the cause by referring to “Diag-
tion point) may be faulty. 5. If the “Accelerator sensor 1” displays less than the
If the intermittent trouble is suspected, followings may specified value when the AP sensor connector is
be the cause. removed, the circuit beyond the sensor is normal
• Improper connection of harness connector including ECM.

Is the “Accelerator sensor 1” more than the speci- Go to “Diagnostic


5 4. Check for “Accelerator sensor 1” on the data 0.1V
Is the “Accelerator sensor 1” less than the specified


1. Check the signal circuit between ECM and AP
sensor 1 for short circuit to the power supply
circuit or ignition power supply circuit using
breaker box or DMM.
ator sensor 1 fault (high voltage fault), List of
Note:
6 —
(high voltage fault), List of Diagnostic Trouble
Codes”.
Important:
If the AP sensor circuit is shorted to the power

box or DMM.
Note:
Codes”.
• Open circuit
• High resistance

8 —
necessary.
Note:
10 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

14 display. 4.9V


display.

(V)
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM

high resistance measurement sensor connector. sensor 1 ground termi- more

3
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
TSWG0197
DTC: P1282 (Flash code 24) Accelerator sensor 2 fault (low voltage fault)
A A Engine control
module (ECM)
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW

20 H-20 19 H-20 18 H-20

TSHK0029

• Ground circuit • DTC P1630, P1282, P1631 is not detected.
power supply circuit, and grounds to the inside of the • AP sensor 2 voltage is 0.2V or less for 1 second or
ECM through ground circuit. Also, the AP sensor out- more.
the AP sensor 2 is less than the normal range.
causes.
Test description
When the DTC P1277 is detected at the same time, the displays less than the specified value. If more than the
tion point) may be faulty. 5. If the “Accelerator sensor 2” displays more than the
If the intermittent trouble is suspected, followings may specified value when terminals between the AP sensor
be the cause. connector are shorted, the circuit beyond the sensor is
• Improper connection of harness connector normal including ECM.



5 4. Turn the key switch to “ON”. 4.8V



between ECM and AP sensor 1 using breaker
box or DMM.
Note:
Codes”.
• Open circuit
• High resistance

between ECM and AP sensor 1 using breaker
box or DMM.
Note:
7 P1282 (Flash code 24) Accelerator sensor 2 fault —
Codes”.
• Short circuit to AP sensor 1 ground circuit
• Open circuit
• High resistance

8 —
necessary.
Note:
10 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

14 display. 0.2V


16 4.8V
display.

(V)
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM

high resistance measurement sensor connector. sensor 1 power sup- more
• Key switch “OFF” ply terminal

high resistance measurement sensor connector. sensor 1 signal termi- more
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1283 (Flash code 24) Accelerator sensor 2 fault (high voltage fault)
A A Engine control
module (ECM)
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW

20 H-20 19 H-20 18 H-20

TSHK0029

power supply circuit, and grounds to the inside of the • AP sensor 2 voltage is 4.9V or more for 1 second
ECM through ground circuit. Also, the AP sensor out- or more.
the AP sensor 2 is more than the normal range.
causes.
Test description
When the DTC P1278 is detected at the same time, the displays more than the specified value. If less than the
tion point) may be faulty. 5. If the “Accelerator sensor 2” displays less than the
If the intermittent trouble is suspected, followings may specified value when the AP sensor connector is
be the cause. removed, the circuit beyond the sensor is normal
• Improper connection of harness connector including ECM.





1. Check the signal circuit between ECM and AP
sensor 1 for short circuit to the power supply
circuit or ignition power supply circuit using
breaker box or DMM.
Note:
6 —
Codes”.
Important:
If the AP sensor circuit is shorted to the power

box or DMM.
Note:
Codes”.
• Open circuit
• High resistance

8 —
necessary.
Note:
10 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

14 display. 4.9V


display.

(V)
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM

high resistance measurement sensor connector. sensor 1 ground termi- more

3
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
TSWG0197
DTC: P1345 (Flash code 16) Cam sensor out of phase
Engine control
module(ECM)
5V
CKP CKP
HIGH LOW
signal signal
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 2 H-20 1 H-20
0.75 Br
0.75 0.75 0.75

0.75 0.75
W/R B/W Br
B/R W/L
2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W
CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSHK0033
Description of circuit • DTC P0335, P0336, P0340, P0341, P1345, or

The crankshaft position (CKP) sensor generates pulse P1635 is not detected.
when the tooth of the flywheel passes the sensor. Also, • Cam pulse is normal.
the camshaft position (CMP) sensor, the same as CKP • Crank pulse is normal.
sensor, generates pulse when the sensing hole for sig-
nal detection installed in the supply pump camshaft DTC set condition
gear passes the sensor.
• Correct CMP sensor pulse does not exist in crank
The ECM sets the DTC when the number of pulses for
gap position.
CKP sensor and CMP sensor are normal but mutual
pulses do not synchronize.
• Behavior does not change during engine running.
• After engine stops, engine will not start.
Preconditions when DTC is set Back-up mode

• Key switch input voltage is 18V or more. • Engine running based on crank when it is normal
• After engine stops: Unable to identify cylinder • Improper connection of harness connector
(unable to restart) • Defective harness routing
• Excessive air mixed in the fuel.
causes.
The conditions to clear the MIL/DTC • Improper connection of harness connector and
ECM connector
dition (recovery from failure). – Unmatched terminals are fitted.
• The diagnosis lamp will go off after the code turns – Damage of connector lock
to history trouble and the key switch is turned – Poor contact between terminal and wire
“OFF” then “ON” again. • Damaged harness
Diagnostic aid
be the cause.

1. Check the CMP sensor condition.
2 • Loose installation and rattling of sensor —

1. Check for the condition of the CKP sensor.
3 • Loose installation and rattling of sensor —


1. Clear the DTC.
clear DTCs.
seconds.
set”.
4. Check the DTC.
4 —
• Stop the engine once, crank the engine for
4 to 5 seconds, and then check if P0340 is
detected.
• If DTC P0340 is detected, judge as an
open circuit in cam sensor, and check and
repair the open circuit in cam sensor. After
repair, crank the engine for 10 seconds,
and confirm that P0340 and P1345 disap-
pear.
Is DTC P1345 detected? Go to Step 5. —

1. Check that the camshaft gear is installed prop-
erly.

1. Check that the flywheel is installed properly.
1. Clear the DTC.
clear DTCs.
seconds.
set”.
4. Check the DTC.

TSHK0129
TSWG0064
Name About CMP sensor

1. GND
2. Power supply
4HK1
Name
1. Signal
TSHK0128 2. GND
3. Power supply
4HK1
15
TSHK0040
6HK1
15
TSWG0152
Name
1. CMP sensor
About CKP sensor and CMP sensor signals
4HK1
TSHK0042
6HK1
TSWG0151
Name
1. CKP signal
2. CMP signal
DTC: P1625 (Flash code 416) Main relay fault
(MAIN)* (30A)*
Battery Main relay
5 E-57 2 E-57 40 E-57 21 E-57
B+ B+
Engine control
module (ECM)
TSWG0071
Description of circuit • DTC P1630 is not detected.

The main relay is installed near the blower motor inside • 3 seconds or more has elapsed after key switch
the instrument panel. The ECM turns the main relay ON.
“ON” when the key switch inputs “ON” signal, and turns • Main relay drive indication ON
the main relay “OFF” when the key switch is “OFF”. • DTC P1625, or P0606 is not detected.
The battery voltage is supplied to the main relay via
fuse, and turning the main relay “ON” will supply the DTC set condition
power supply voltage to the ECM.
The ECM sets the DTC when the output to/input from • Main relay input power supply voltage is 1 V or
the main relay do not match. less for 2 seconds or more.
• Relay does not cut off for 5 seconds or more even
Main trouble symptom after the main relay coil OFF command is sent.
Engine does not start or power supply cannot be shut
off. Action taken when DTC is set
Preconditions when DTC is set machine or diagnosis lamp comes on.
causes.
• Damaged harness
• The diagnosis lamp will go off after the code turns ness which are related to the sensor. The varia-
to history trouble and the key switch is turned tion of the display indicates the faulty part.
• Using the scan tool, or memory clear switch and Test description
4. If the main relay is stuck closed, it is possible to com-
Diagnostic aid
municate with ECM using scan tool even with the key
If the intermittent trouble is suspected, followings may switch “OFF”.
be the cause. 5. If it is still possible to communicate with ECM using
• Fault in switch body scan tool and the DTC is detected when the main relay
• Improper adjustment of switch is removed, the circuit beyond the relay or ECM is
faulty.
8. If the “Main relay voltage” displays more than the
• Defective harness routing specified value when terminals between the main relay
• Worn harness cladding installing portion are shorted, the circuit beyond the
• Wire disconnection inside harness cladding relay is normal including ECM.

2. Check for “Main relay voltage” on the data dis-
3 play using scan tool. 1V
Is the “Main relay voltage” more than the specified
Go to “Diagnostic
1. Remove the main relay.
2. Check the DTC.
Note:
5 Refer to the machine’s manual for installing posi- —
tion and installation/removal procedures of the
main relay.


1. Check the circuit (contact point side) between
main relay and ECM for short circuit to the
cedure, DTC: P1625 (Flash code 416) Main
relay fault, List of Diagnostic Trouble Codes”.
6 Note: —
P1625 (Flash code 416) Main relay fault, List of

Check for installation condition of the main relay,


3. Short between the terminals 1 - 2 and 3 - 5 in
the main relay installing portion respectively
using jump cable.
8 24V
5. Check for “Main relay voltage” on the data dis-
play using scan tool.
Is the “Main relay voltage” more than the specified

1. Check for following in the circuit between slow-
blow fuse and main relay.
• Open circuit
• High resistance

main relay and ECM using breaker box or
DMM.
Note:
• Open circuit
• High resistance


Replace the main relay.
11 —
necessary.
Note:
13 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

17 4. Connect the DMM between the main relay 1V
connector coil-side terminal and the ground.

Go to “Diagnostic

2. Check the DTC.
Note:
19 Refer to the machine’s manual for installing posi- —
tion and installation/removal procedures of the
main relay.

1. Check the circuit (contact point side) between
main relay and ECM for short circuit to the
20 Note: —

Check for installation condition of the main relay,


4. Connect the DMM between the main relay
22 24V
connector terminal (contact point side) and the
ground.

Name
1. Breaker box
2. DMM

power supply surement relay. 5 – Ground
10 Open circuit/ Resistance • Disconnect the 2 – Relay installing ter- 100Ω or less 10 MΩ or
high resistance measurement relay. minal No. 2 more
• Key switch “OFF” 5 – Relay installing ter-
minal No. 2
21 – Relay installing
terminal No. 5
40 – Relay installing
terminal No. 5
ground measurement relay. 5 – Ground more
40 – Ground
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1630 (Flash code 36) A/D conversion fault
The ECM processes the analog signals (voltage signal • Analog sensor system default processing
etc.) which are input from each sensor into digital sig- • Limited injection amount 3 (multi-injection stopped)
nals, to perform various controls and calculations.
• Target RP upper limit (80 MPa {11603 psi})
The ECM sets the DTC when the fault is detected for
the analog/digital conversion.
Main trouble symptom Refer to 1E-284, “List of Diagnostic Trouble Codes”
• Output lowering
DTC set condition
• Analog/digital conversion failure the condition is out of the range from DTC set con-
Action taken when DTC is set • The diagnosis lamp will go off after the code turns
• Trouble is displayed on the monitor of the to history trouble and the key switch is turned
machine or diagnosis lamp comes on. “OFF” then “ON” again.

1. Clear the DTC.
clear DTCs.

seconds.
set”.
4. Check the DTC.
Go to “Diagnostic
necessary.
Note:
4 —


Replace the ECM.
Note:

DTC: P1631 (Flash code 55) Voltage fault in 5-V power supply 1
A A Engine control
module (ECM)
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW

20 H-20 19 H-20 18 H-20

TSHK0029

The 5-V power supply circuit is provided to the ECM for • Key switch power supply voltage is 5.5 V or more,
5 systems. The 5-V power supply circuit 1 supplies or 4.5 V or less for 0.5 seconds or more.
power to the accelerator position (AP) sensor.
The ECM sets the DTC when the voltage in the 5-V Action taken when DTC is set
power supply circuit 1 is higher or lower than the nor-
mal range. machine or diagnosis lamp comes on.
Idling
Back-up mode
Preconditions when DTC is set • Same to accelerator sensor fault
• DTC P1630 is not detected.
• Key switch input power supply voltage is higher Recovery from failure
than 16 V but lower than 32 V. Refer to 1E-284, “List of Diagnostic Trouble Codes”
The conditions to clear the MIL/DTC • Using the scan tool, or memory clear switch and
dition (recovery from failure). Test description
• The diagnosis lamp will go off after the code turns Numbers below indicate step numbers in the chart.
to history trouble and the key switch is turned 2. Measure at the harness connector-side.
“OFF” then “ON” again. 3. Measure at the harness connector-side.

3. Connect the DMM between the AP sensor
2 power supply terminal and the ground. 5.5V

3. Connect the DMM between the AP sensor
3 power supply terminal and the ground. 4.5V

1. Check the power supply circuit between AP
sensor 1 and ECM for short circuit to the bat-
tery power supply circuit or ignition power sup-
cedure, DTC: P1631 (Flash code 55) Voltage
fault in 5-V power supply 1, List of Diagnostic
Trouble Codes”.
4 —
Note:
P1631 (Flash code 55) Voltage fault in 5-V power
supply 1, List of Diagnostic Trouble Codes”.

1. Check the power supply circuit between AP
sensor 1 and ECM for ground short circuit
Trouble Codes”.
5 Note: —


necessary.
Note:
7 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

Name
1. Breaker box
2. DMM

4 Short circuit to Voltage mea- • Remove the ECM. 42 – Ground 0V 1V or more
power supply surement • Key switch “ON”
circuit
5 Short circuit to Resistance • Remove the sen- 42 – Ground 10 MΩ or 100Ω or less
ground circuit/ measurement sor. more
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness
A A Engine control
module (ECM)
CAN LOW CAN HIGH
5V 5V
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW

20 H-20 19 H-20 18 H-20

TSHK0029

power to the barometric pressure sensor.
power supply circuit 2 and 5 is higher or lower than the
normal range. machine or diagnosis lamp comes on.
Due to back-up equivalent to 2000 m (6562 ft)
• Black smoke emitted at high altitude Back-up mode
• Output shortage at low altitude • Same to barometric pressure and intake air tem-
perature sensor fault
• Key switch input power supply voltage is higher Refer to 1E-284, “List of Diagnostic Trouble Codes”
than 16 V but lower than 32 V. and “About recovery from failure” in this section for

connector.
3. Connect the DMM between the barometric
2 pressure sensor power supply terminal and the 5.5V
ground.

connector.
3. Connect the DMM between the barometric
ground.
Is the DMM indication less than the specified Go to “Diagnostic

1. Check the power supply circuit between baro-
metric pressure sensor and ECM for short cir-
cuit to the battery power supply circuit or
or DMM.
4 Trouble Codes”. —
Note:


1. Check the power supply circuit between baro-
metric pressure sensor and ECM for ground
short circuit using breaker box or DMM.
Trouble Codes”.
5 Note: —

necessary.
Note:
7 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

Name
1. Breaker box
2. DMM

circuit
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

5V

108 E-56 107 E-56 106 E-56 19 E-57 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
3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
2 E-98 1 E-98
Engine
coolant
temperature
pressure sensor
CKP sensor
A
Engine control
0.75
R
37 E-57 18 E-57
4 H-6
Vehicle
speed sensor A
Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
TSHK0030
Description of circuit • Key switch input power supply voltage is higher

The 5-V power supply circuit is provided to the ECM for than 16 V but lower than 32 V.
5 systems. The 5-V power supply circuit 3 supplies
power to the engine oil pressure sensor. DTC set condition
The ECM sets the DTC when the voltage in the 5-V • Key switch power supply voltage is 5.5 V or more,
power supply circuit 3 is higher or lower than the nor- or 4.5 V or less for 0.5 seconds or more.
mal range.
• At normal temperature: Black smoke emission, machine or diagnosis lamp comes on.
greater engine combustion noise possible.
• During idling at low atmospheric temperatures:
Rough idling, engine stall, white smoke emission
possible. Back-up mode
• Same to oil pressure, coolant temperature, and
Preconditions when DTC is set combustion temperature sensor fault
Test description
dition (recovery from failure). 2. Measure at the harness connector-side.
3. Measure at the harness connector-side.

connector.
3. Connect the DMM between the engine oil
ground.

connector.
3. Connect the DMM between the engine oil
ground.

1. Check the power supply circuit between
engine oil pressure sensor and ECM for short
circuit to the battery power supply circuit or
or DMM.
Note:


1. Check the power supply circuit between
engine oil pressure sensor and ECM for
DMM.
Trouble Codes”.
5 —
Note:

necessary.
Note:
7 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

Name
1. Breaker box
2. DMM

circuit
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
74 E-56 109 E-56 91 E-56 95 E-56
15 H-20 17 H-20 16 H-20 8 H-20
0.75 0.75 0.75 0.75 0.75

B/R R/L R/L L R/W
2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

TSWG0079

power to the boost pressure sensor.
normal range. machine or diagnosis lamp comes on.
Black smoke emitted
Back-up mode
Preconditions when DTC is set • Same to boost pressure and boost temperature
• DTC P1630 is not detected. sensor fault
• Key switch input power supply voltage is higher
than 16 V but lower than 32 V. Recovery from failure

tor.
3. Connect the DMM between the boost pressure
2 sensor power supply terminal and the ground. 5.5V

tor.
3. Connect the DMM between the boost pressure
3 sensor power supply terminal and the ground. 4.5V

1. Check the power supply circuit between boost
the battery power supply circuit or ignition
power supply circuit using breaker box or
DMM.
Note:


1. Check the power supply circuit between boost
pressure sensor and ECM for ground short cir-
cuit using breaker box or DMM.
Trouble Codes”.
5 Note: —

necessary.
Note:
7 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

Name
1. Breaker box
2. DMM

circuit
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine control
module (ECM)
5V
B+ B+ B+
99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR valve
TSHK0028
Description of circuit • Key switch input power supply voltage is higher

The 5-V power supply circuit is provided to the ECM for than 16 V but lower than 32 V.
5 systems. The 5-V power supply circuit 5 supplies
power to the common rail pressure sensor and the DTC set condition
EGR position sensor. • Key switch power supply voltage is 5.5 V or more,
The ECM sets the DTC when the voltage in the 5-V or 4.5 V or less for 0.5 seconds or more.
normal range. Action taken when DTC is set
• Engine blow up
• Output lowering
Back-up mode
• Engine stall possible
• Same to rail pressure sensor fault and EGR posi-
Preconditions when DTC is set tion sensor fault

Test description
dition (recovery from failure). 2. Measure at the harness connector-side.
3. Measure at the harness connector-side.

connector.
ground.

connector.
ground.

1. Check the power supply circuit between com-
mon rail pressure sensor and ECM for short
circuit to the battery power supply circuit or
or DMM.
Note:


1. Check the power supply circuit between com-
mon rail pressure sensor and ECM for ground
short circuit using breaker box or DMM.
Trouble Codes”.
5 Note: —

necessary.
Note:
7 —

Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.

Name
1. Breaker box
2. DMM

circuit
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness
DTC: U2104 (Flash code 84) CAN Bus fault
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150
DLC Machine
control unit
5 FL-150 4 FL-150
CAN HIGH CAN LOW
TSHK0023

The ECM communicates with the machine control unit • Key switch input voltage is 12 V or more.
(ECU) through CAN communication circuit. The ECM
data outputs through the CAN-High circuit, and other Action taken when DTC is set
ECU data inputs through the CAN-Low circuit. The
CAN communication performs at a constant speed
without interruption, and the number of data outputs
and inputs must always be the same.
The ECM sets the DTC when the fault is detected for
the CAN communication.
Back-up mode
Main trouble symptom • Specified back-up value
Set to idle speed.
DTC set condition
• Revolution command message of CAN communi-
cation is disrupted for 1 second or more.
The conditions to clear the MIL/DTC Test description
• The present trouble turns to history trouble when Numbers below indicate step numbers in the chart.
the condition is out of the range from DTC set con- 2. If no DTC is detected, intermittent trouble is sus-
dition (recovery from failure). pected. Identify the cause by referring to “Diagnostic
• Using the scan tool, or memory clear switch and aid”.
diagnostic switch operation enables to clear DTCs. 3. Measure at the harness connector-side.

Perform the OBD check.
seconds.

3. Check the DTC.
Go to “Diagnostic
Is DTC U2104 detected? Go to Step 3. aid”.
1. If the DTC U2104 is detected, and the history
and present troubles of DTC U2106 are alter-
nately detected, check the circuit between
ECM terminals (32) and (18) for the following
conditions.
3 • Short circuit —
required.
3. Check if DTC is not detected again.

4 Is the breaker box available? — Go to Step 5. Go to Step 15.
2. Remove the ECM.
3. Connect the breaker box to the ECM.
4. Connect the breaker box with the ECM har-
5 ness. 50 — 70Ω
5. Measure the resistance between the CAN-
High-side terminal and CAN-Low-side terminal
using breaker box.
Is the resistance within the specified value? Go to Step 13. Go to Step 6.

1. Remove the ECM from the breaker box.
6 High-side terminal and CAN-Low-side terminal Approx. 120Ω
using breaker box.

1. Connect the ECM to the breaker box.
2. Remove the machine control unit and the har-
ness.
7 3. Measure the resistance between the CAN- Approx. 120Ω
High-side terminal and CAN-Low-side terminal
using breaker box.


1. Check the CAN-Low circuit and CAN-High cir-
cuit between ECM and machine control unit for
short circuit to the power supply circuit or igni-
tion power supply circuit using breaker box or
DMM.
cedure, DTC: U2104 (Flash code 84) CAN Bus
fault, List of Diagnostic Trouble Codes”.
8 —
Note:
U2104 (Flash code 84) CAN Bus fault, List of Diag-
2. If the trouble is detected, replace the harness.

1. Check for followings in the CAN-Low circuit
and CAN-High circuit between ECM and
machine control unit using breaker box or
DMM.
cedure, DTC: U2104 (Flash code 84) CAN Bus
fault, List of Diagnostic Trouble Codes”.
Note:
U2104 (Flash code 84) CAN Bus fault, List of Diag-
• Open circuit
• High resistance
2. If the trouble is detected, repair as required. Replace the
machine control
Is the trouble detected? Go to Step 2. unit.
necessary.
Note:
11 —

Replace the ECM.
Note:


2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.
Is DTC U2104 detected? Go to Step 2. Go to Step 14.

Remove the ECM, and measure the resistance
between the CAN-High-side terminal and CAN-
15 Low-side terminal of the ECM connector. Approx. 120Ω

1. Install the ECM, and remove the machine con-
trol unit.
16 High-side terminal and CAN-Low-side terminal Approx. 120Ω
of the machine control unit connector.

Name
1. Breaker box
2. DMM

8 Short circuit to Voltage mea- • Remove all the rel- 18 – Ground 0V 18V or more
power supply surement evant ECU con- 37 – Ground
circuit nectors.

9 Open circuit/ Resistance • Remove all the rel- 37 – Machine control 100Ω or less 10 MΩ or
high resistance measurement evant ECU con- unit more
nectors. 18 – Machine control
• Key switch “OFF” unit
Short circuit to Resistance • Remove all the rel- 18 – Ground 10 MΩ or 100Ω or less
ground measurement evant ECU con- 37 – Ground more
nectors.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: U2106 (Flash code 85) CAN timeout fault
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150
DLC Machine
control unit
5 FL-150 4 FL-150
CAN HIGH CAN LOW
TSHK0023

The ECM communicates with the machine control unit • Revolution command message of CAN communi-
(ECU) through CAN communication circuit. The ECM cation is disrupted for 1 second or more.
data outputs through the CAN-High circuit, and other
ECU data inputs through the CAN-Low circuit. The Preconditions when DTC is set
CAN communication performs at a constant speed
• DTC U2104 is not detected.
without interruption, and the number of data outputs
and inputs must always be the same. • Key switch input voltage is 20 V or more.
The ECM sets the DTC when the CAN communication
is disrupted with the machine control unit (ECU). Action taken when DTC is set
• It cannot be controlled from the machine side since
CAN communication is disabled. The engine
speed becomes back-up speed specified by each
machine manufacturer. Back-up mode
• Specified back-up value
Recovery from failure Following inspections are necessary to detect these
causes.
and “About recovery from failure” in this section for • Improper connection of harness connector and
recovery from failure. ECM connector
• Damaged harness
diagnostic switch operation enables to clear DTCs. – Visually check the harness for damage.
Diagnostic aid display while moving the connector and the har-
be the cause.
• Improper connection of harness connector Test description
• Defective harness routing Numbers below indicate step numbers in the chart.
• Worn harness cladding 2. If no DTC is detected, intermittent trouble is sus-
• Wire disconnection inside harness cladding pected. Identify the cause by referring to “Diagnostic
aid”.

seconds.

3. Check the DTC.
Go to “Diagnostic
machine control unit (ECU) using breaker box
or DMM.
cedure, DTC: U2106 (Flash code 85) CAN tim-
eout fault, List of Diagnostic Trouble Codes”.
Note:
U2106 (Flash code 85) CAN timeout fault, List of
• Open circuit
• High resistance


machine control unit (ECU) using breaker box
or DMM.
cedure, DTC: U2106 (Flash code 85) CAN tim-
eout fault, List of Diagnostic Trouble Codes”.
Note:
U2106 (Flash code 85) CAN timeout fault, List of

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.
Go to “Diagnostic
1. If the DTC U2104 is detected, and the history
and present troubles of DTC U2106 are alter-
nately detected, check the circuit between
ECM terminals (32) and (18) for the following
conditions.
6 • Short circuit —
required.
3. Check if DTC is not detected again.

Replace the machine control unit.
7 —
necessary.
Note:
9 —


Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
seconds.
set”.
5. Check the DTC.
Is DTC U2106 detected? Go to Step 2. Go to Step 12.


Name
1. Breaker box
2. DMM

4 Open circuit/ Resistance • Remove the 18 – Machine control 100Ω or less 10 MΩ or
high resistance measurement machine control unit (ECU) connector more
unit (ECU) connec- terminal
tor. 37 – Machine control
• Key switch “OFF” unit (ECU) connector
terminal

5 Short circuit to Resistance • Remove the 18 – Ground 10 MΩ or 100Ω or less
ground measurement machine control 37 – Ground more
unit (ECU) connec-
tor.
Short circuit to Voltage mea- • Remove the 18 – Ground 0V 18V or more
power supply surement machine control 37 – Ground
circuit unit (ECU) connec-
tor.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
List of Trouble Symptom

List of trouble symptom
Symptom Description
Engine start failure Crank speed is slow.
Crank speed is normal but engine does not start (no first combustion).
Engine starts (first combustion exists) but cannot maintain stable
engine speed, or no blow up.
Engine stall Engine cranks but take long time before start. It operates eventually,
or starts but stops immediately.
Engine hunting, rough idling Engine idle speed is rough, or idle speed changes. In a more severe
case, engine or machine vibrates. In any serious situations, the
engine stalls.
Engine output shortage, lag down Engine output is lower than expected, and output does not change
with the accelerator lever (throttle lever) released, engine response
deteriorates.
Exhaust gas contains a lot of white smoke. A lot of white smoke emitted while running.
Exhaust gas contains a lot of black smoke. A lot of black smoke emitted while running.
Noise Abnormal sound occurs from the engine.
Fuel consumption deteriorates. Fuel consumption is remarkably more than that indicated in the
machine’s manual. The situation shown here is that the problem is
not found on the machine side and the engine needs to be checked.
Oil consumption deteriorates. Oil consumption is remarkably lower than that indicated in the
machine’s manual. The situation shown here is that the problem is
not found on the machine side and the engine needs to be checked.
Engine start failure
Pre-inspection • Exhaust system parts for fault.
Before using this paragraph, perform the “OBD system
check” and check all the following items. Diagnostic aid
• Check if excessive load is applied to the machine • If the crank sensor is faulty, crank more than 60
side. rpm for 14 seconds or more since it is not judged
on cranking for less than 14 revolutions.
• ECM and diagnosis lamp operate properly.
• When the engine is running at low speed, the DTC
• Check the DTC.
of crank sensor fault may not be detected. If an
• Scan tool data shows normal operating range. intermittent trouble is found, raise the engine
• Check the condition of the machine to identify the speed up to No Load Max, and check if DTC
applicable symptom from “List of trouble symp- related to crank sensor is detected.
tom”. Perform the procedure described in the • Fuel system fault (run out of fuel, frozen fuel, air
symptom chart. mixed in fuel pipe, faulty filter [clog in main filter,
• Check with the customer if correct engine oil and gauze filter], pipe fault, fuel quality, fuel tank [for-
fuel are used. eign matter, fuel suction fault])
• Intake system fault (clogging in filter, intake pipe
Visual check fault, etc.)
Careful visual check is required for some symptom pro- • Supply pump fault (no fuel pressure feed)
cedures. By this inspection, the problem can be cor- • Common rail fault (flow damper or pressure limiter
rected without performing further inspection, and time is activated, degradation of sealability)
can be saved.
• Injector fault (no fuel injection)
This inspection includes the following items.
• There is no dirt or clogging in fuel filter. • System down due to trouble
• Engine body fault
• There is no poor contact in connector (it must be
(seizure, compression pressure shortage, other
connected with click sound). Especially for CKP
mechanical trouble)
sensor and CMP sensor.
• ACG trouble
• The terminal voltage of battery is not low.
• Machine side related equipment trouble
• Wire is connected, tightened or cut properly.
(oil pressure pump etc.)
• Commercial accessory power supply is not bifur-
• Effect of commercial electrical equipment (radio,
cated from ECM power supply.
lamp, etc.)
• ECM ground is not contaminated and installed to
the proper position securely. • ECM trouble
(body, power supply, ground, etc.)
• Pipes and hoses relevant to fuel, air and oil are
• Check the connector for poor contact, the harness
free of crack or twist, and are properly connected.
for fault such as wear or bend, and the wire inside
Thoroughly check for any oil leakage and clogging.
the harness for loosened wire causing short circuit
• Fuel system is free from oil leakage, and pipe is to other circuits. Also, perform the function diagno-
not damaged or dent. sis to check the operation and control of each part.
• Intake system parts for fault. Repair if faulty.

Check if following DTCs are detected.
3 DTC: P0335, P0336, P0340, P0341, P0601, —
P1261, P1262 Go to the related
“Inspection method
Is DTC detected? by DTC”. Go to Step 4.

Check the crank speed.
Check if the crank speed is more than the neces-
4 sary speed for ECM to identify engine rotation. 60 rpm
Is the crank speed more than specified value? Go to Step 5. Go to Step 6.

Check the crank speed.
Check if the crank speed is more than the neces-
5 sary speed to start the engine (first combustion). 80 rpm
Is the crank speed more than specified value? Go to Step 7. Go to Step 6.

Check the starting system.
6 — Go to “Starting sys-
Is the procedure completed? Go to Step 7. tem check”.
gauze filter)
• Fuel tank (pump strainer)
7 2. Check the fuel pipe, fuel filter, and inside of the —
ature)
• If opaque frosty object is found in the filter
part of the main filter, waxing may occurs.
Replace fuel.

Check the injector.
1. Clear the DTC.
clear DTCs.
the scan tool menu.
8 When the scan tool is not available, refer to —
1E-82, “How to Inspect Injector” in this section.

Note:
service manual.


Check the ACG.
Check if the charge warning lamp turns on while
engine is running.
10 Note: —
Refer to the machine’s manual for charge warning.
Does the charge warning operate? Go to Step 12. Go to Step 11.

Replace the ACG. Also, check the charge warning
11 system, and repair or replace if faulty. —
Check the condition of commercial electrical equip-
ment such as radio and lights.
12 —
Does the engine start when the commercial electri-
cal equipment is powered OFF? Go to Step 13. Go to Step 14.
Correct the installation condition of the electrical
13 equipment, or remove the electrical equipment. —
Check the mechanical part of the engine, and
repair if faulty.
• Compression pressure
• Valve system
• Injector
14 • Timing gear —
• Related parts of piston/crank
Note:
service manual.

necessary.
Note:
16 —

Replace the ECM.
Note:

Engine stall
Pre-inspection • Pipes and hoses relevant to fuel, air and oil are
check” and check all the following items.
• Fuel system is free from oil leakage, and pipe is
• Check if excessive load is applied to the machine
not damaged or dent.
side.
• ECM and diagnosis lamp operate properly. • Intake system parts for fault.
• Exhaust system parts for fault.
• To detect crank sensor fault, crank more than 60
rpm for 14 seconds or more since it is not judged
on cranking for less than 14 revolutions. Diagnostic aid
• Check the DTC. • Fuel system fault (run out of fuel, frozen fuel, air
mixed in fuel pipe, faulty filter [clog in main filter,
• When the engine is running at low speed, the DTC
gauze filter], pipe fault, fuel quality, fuel tank [for-
of crank sensor fault may not be detected. If an
eign matter, fuel suction fault])
intermittent trouble is found, raise the engine
speed up to No Load Max, and check if DTC • Intake system fault (clogging in filter, intake pipe
related to crank sensor is detected. fault, etc.)
• Scan tool data shows normal operating range. • Supply pump fault (no fuel pressure feed)
• Check the condition of the machine to identify the • Common rail fault (flow damper or pressure limiter
applicable symptom from “List of trouble symp- is activated, degradation of sealability)
tom”. Perform the procedure described in the • Injector fault (no fuel injection)
symptom chart. • System down due to trouble
• Check with the customer if correct engine oil and • Engine body fault
fuel are used. (seizure, compression pressure shortage, other
mechanical trouble)
Visual check • ACG trouble
Careful visual check is required for some symptom pro- • Machine side related equipment trouble
cedures. By this inspection, the problem can be cor- (oil pressure pump etc.)
rected without performing further inspection, and time
can be saved.
lamp, etc.)
• ECM trouble
• There is no poor contact in connector (it must be
(body, power supply, ground, etc.)
connected with click sound). Especially for CKP
sensor and cam sensor. • Check the connector for poor contact, the harness
for fault such as wear or bend, and the wire inside
• Commercial accessory power supply is not bifur- to other circuits. Also, perform the function diagno-
cated from ECM power supply. sis to check the operation and control of each part.
• ECM ground is not contaminated and installed to Repair if faulty.
the proper position securely.

Check if excessive load is applied to the machine
side.
2 Note: —
Refer to the machine’s manual for check and
repair.


Check the electrical system.
1. Crank sensor fault is not judged on cranking
for less than 14 revolutions. Crank the engine
at 60 rpm or more for 14 seconds or more, or
raise the engine speed up to No Load Max,
and check if DTC is detected.
2. Check the connectors of the ECM, fuel pump,
ACG and electronic governor for poor contact
3 or play. —
Note:
Poor contact in the connector, especially CKP sen-
sor and CMP sensor, causes engine stall. It must
be connected with click sound.
3. Check the harness for open or short circuit.

Check the ACG.
Check if the charge warning lamp turns on while
engine is running.
4 Note: —
Refer to the machine’s manual for charge warning.
Does the charge warning operate? Go to Step 6. Go to Step 5.

Replace the ACG. Also, check the charge warning
5 system, and repair or replace if faulty. —
6 —
Does the engine stall when the commercial electri-
cal equipment is powered OFF? Go to Step 7. Go to Step 8.
gauze filter)
• Fuel tank (pump strainer)
8 • Fuel system pipe —
ature)

Check the intake system.
9 — Go to “Intake sys-

Check the exhaust system.
10 — Go to “Exhaust sys-
repair if faulty.
• Valve system
11 • Injector —
• Timing gear

necessary.
Note:
13 —

Replace the ECM.
Note:

Engine hunting, rough idling
Pre-inspection • Fuel system is free from oil leakage, and pipe is
check” and check all the following items. • Intake system parts for fault.
• ECM and diagnosis lamp operate properly. • Exhaust system parts for fault.
• Check the DTC.
Diagnostic aid
• Scan tool data shows normal operating range.
• Fuel system fault (run out of fuel, frozen fuel, air
• Check the condition of the machine to identify the
applicable symptom from “List of trouble symp-
tom”. Perform the procedure described in the
symptom chart.
• Intake system fault (clogging in filter, intake pipe
• Check with the customer if correct engine oil and
fault, etc.)
fuel are used.
• Supply pump (including feed pump) fault (no fuel
Visual check pressure feed)
• Switch input circuit system fault
Careful visual check is required for some symptom pro-
cedures. By this inspection, the problem can be cor- • Sensor input circuit system fault (accelerator posi-
rected without performing further inspection, and time tion (AP) sensor, harness, engine coolant temper-
can be saved. ature (ECT) sensor, etc.)
This inspection includes the following items. • AP sensor system fault (sensor, harness, etc.)
• There is no poor contact in connector (it must be • Engine body fault (seizure, compression pressure
connected with click sound). shortage, other mechanical trouble)
• The terminal voltage of battery is not low. • Machine side related equipment trouble (oil pres-
• Wire is connected, tightened or cut properly. sure pump etc.)
• Commercial accessory power supply is not bifur- • Effect of commercial electrical equipment (radio,
cated from ECM power supply. lamp, etc.)
• ECM ground is not contaminated and installed to • Check the connector for poor contact, the harness
the proper position securely. for fault such as wear or bend, and the wire inside
to other circuits. Also, perform the function diagno-
Repair if faulty.

side.
2 Note: —
repair.

Check the fuel.
1. Supply fuel from a container other than the fuel
tank.
3 2. Start the engine, operate the machine, and —
check for trouble symptom.
3. Replace the fuel in the fuel tank and pipe.
Is the engine symptom corrected? Go to Step 24. Go to Step 4.


Bleed air from fuel, and check for trouble symptom
again.
Note:
service manual.

Check the fuel system.
6 — Go to “Fuel system
Check the injector.
1. Clear the DTC.
clear DTCs.
the scan tool menu.

Note:
service manual.

Check for the engine symptom again.
9 —
10 —
Does the engine symptom change when the com-
mercial electrical equipment is powered OFF? Go to Step 11. Go to Step 12.
position (CKP) sensor and camshaft position
(CMP) sensor.
12 Check the CKP sensor and CMP sensor for —
improper installation such as play.
Is it properly installed? Go to Step 14. Go to Step 13.

Correct the installation conditions of the CKP sen-
13 sor and CMP sensor. —

Check the signal conditions of CKP sensor and
CMP sensor using scan tool.
15 2. Crank the engine. —
3. Correct the data list on the scan tool.
Is the speed displayed? Go to Step 18. Go to Step 16.

Check for signal detection condition of the CKP
sensor.
2. Remove the harness from the CMP sensor.
16 —
(The DTC is detected when this procedure is
performed. Be sure to clear the DTC after
repairing the machine.)
Is the idle condition normal? Go to Step 23. Go to Step 17.

Check for signal detection condition of the CMP
sensor.
2. Remove the harness from the CKP sensor.
17 (The DTC is detected when this procedure is —
performed. Be sure to clear the DTC after
repairing the machine.)
Is the idle condition normal? Go to Step 23. Go to Step 18.

18 —
necessary.
Note:
20 —

Replace the ECM.
Note:


Restore the ECM to its original condition of before
replacement.
Note:
22 replacing or rewriting the ECM. —

repair if faulty.
• Valve system
23 • Flywheel —
• Camshaft gear
• Timing gear

Repair the machine, and check the repair.
24 —
Engine output shortage
Pre-inspection • Sensor input circuit system fault (accelerator posi-
tion (AP) sensor, harness, etc.)
check” and check all the following items. • Switch input circuit system fault
• ECM and diagnosis lamp operate properly. • Engine body fault (compression pressure, valve
• Check the DTC. clearance, turbocharger, supply pump, injector,
common rail and other mechanical trouble, etc.)
• Scan tool data shows normal operating range.
• Machine side related equipment trouble (oil pres-
• Check the condition of the machine to identify the sure pump etc.)
applicable symptom from “List of trouble symp-
lamp, etc.)
symptom chart.
• Check with the customer if correct engine oil and • Check the connector for poor contact, the harness
fuel are used. for fault such as wear or bend, and the wire inside
Various kinds of causes are assumed for output short- the harness for loosened wire causing short circuit
age, therefore thoroughly investigate the relation to other circuits. Also, perform the function diagno-
between engine body and machine. sis to check the operation and control of each part.
Repair if faulty.
• Check what operation triggers the output shortage.
• Output lowering due to regulated fuel flow during
If hesitations or lag down is included in the symptom of
overheat
the output shortage, the fault is related to the machine-
side control. Contact with Hitachi Construction Machinery. • Output shortage due to regulated fuel flow at high
If Tech2 is available, checking the boost of Q enables altitude
to check the engine output at rated point as a simplified
method. Control during overheat
In overheating, ECM begins to limit fuel flow when the
Visual check engine coolant temperature exceeds 108°C (226°F),
for engine protection. It limits fuel flow further as the
engine coolant temperature goes up. Fuel flow is lim-
cedures. By this inspection, the problem can be cor-
ited to a certain level at around 120°C (248°F).
The system raises an alarm from 105°C (221°F) for
can be saved.
some machines. In addition to alarm, by reducing the
load to the machine, it enables to avoid such conditions
• There is no dirt or clogging in air cleaner element. that the fuel flow is limited.
• Commercial accessory power supply is not bifur-
• ECM ground is not contaminated and installed to
(226 )
Thoroughly check for any oil leakage and clogging. 100%

Fuel fiow
• Increase in resistance due to dirt or clogging in

(248 )
intake system parts (especially air cleaner ele-
ment) and crushed intake pipes
Diagnostic aid (221 )

mixed in fuel pipe, faulty filter [clog in main filter, TSWG0169
eign matter, fuel suction fault]) About high-altitude correction
• Intake system fault (clogging in filter, intake pipe ECM calculates the current altitude based on the baro-
fault, etc.) metric pressure sensor signal.
• Exhaust system fault (exhaust brake, exhaust pipe
fault, etc.)
It regulates the opening/closing period of PCV or elec-
tric conduction of injector according to the altitude etc.
at this time, to correct the optimum fuel flow.
Fuel flow limit (mm 3/st)

Barometric pressure kPa(psi)
highland
TSWG0173

1. Make sure that the engine coolant temperature
does not exceed 108°C (226°F).
2. Examine and repair the cause of overheat.
2 —
3. Lower the engine coolant temperature to make
sure that the output lowering has corrected.

Check driving environment.
Fuel flow may be limited by correction when driving Contact the
3 at high altitude. — Hitachi Construction
Machinery for
Did you drive at high altitude? countermeasure. Go to Step 4.
side.
4 Note: —
repair.

Check the fuel.
1. Replace the fuel in the fuel tank and pipe.
5 2. Start the engine, operate the machine, and —

Bleed air from fuel, and check for trouble symptom
again.
Note:
service manual.


10 —
11 —
Does the engine symptom change when the com-
mercial electrical equipment is powered OFF? Go to Step 12. Go to Step 13.
13 —
Check the injector.
1. Clear the DTC.
clear DTCs.
the scan tool menu.

Note:
service manual.

necessary.
Note:
17 —


Replace the ECM.
Note:

replacement.
Note:
19 replacing or rewriting the ECM. —

repair if faulty.
• Valve system
20 • Injector —
• Timing gear

Check the machine-side equipment (trouble of oil
21 pressure pump etc.), and repair if faulty. —
22 —
Exhaust gas contains a lot of white smoke.
Pre-inspection • Commercial accessory power supply is not bifur-
check” and check all the following items. • ECM ground is not contaminated and installed to
• Check the DTC. • Pipes and hoses relevant to fuel, air and oil are
• Scan tool data shows normal operating range. Thoroughly check for any oil leakage and clogging.
• Check the condition of the machine to identify the • Fuel system is free from oil leakage, and pipe is
applicable symptom from “List of trouble symp- not damaged or dent.
• Intake system parts for fault.
symptom chart.
• Check with the customer if correct engine oil and • Exhaust system parts for fault.
fuel are used.
Diagnostic aid
Visual check • Fuel quality (use of fuel other than specified)
Careful visual check is required for some symptom pro- • Long-term idling
cedures. By this inspection, the problem can be cor- • Trouble of engine coolant temperature (ECT) sen-
rected without performing further inspection, and time sor, fuel temperature (FT) sensor, intake air tem-
can be saved. perature (IAT) sensor, boost pressure sensor, or
This inspection includes the following items. barometric pressure sensor.
• There is no poor contact in injector connector (it • Engine body trouble (compression pressure short-
must be connected with click sound). age, related to piston, turbocharger, rise/decline of
• Wire is connected, tightened or cut properly. oil, etc.)
• ECM trouble (body, power supply, ground, etc.)

Check the fuel.
1. Replace the fuel tank and the fuel in the pipe,
or supply the specified oil suitable for current
2 environment from the fuel container. —
2. Start the engine, operate the machine, and

Check if oil is mixed in the intake air.
1. Is the blow-by emitted excessively?
• Excessive engine oil
• Clogged or deformed oil return pipe
4 • Clogged or crushed breather hose —
2. Wear of turbocharger seal ring



Check the injector.
1. Clear the DTC.
clear DTCs.
6 the scan tool menu. —

Perform the pre-injection stop test.
Select the “Stop pre-injection” from the scan tool
7 menu to perform the test. —

Note:
service manual.

10 —
necessary.
Note:
12 —


Replace the ECM.
Note:

14 replacement. —
repair if faulty.
• Valve system
15 • Injector —
• Timing gear

16 —
Exhaust gas contains a lot of black smoke.
Pre-inspection • Commercial accessory power supply is not bifur-
check” and check all the following items. • ECM ground is not contaminated and installed to
• Check the DTC. • Pipes and hoses relevant to fuel, air and oil are
• Scan tool data shows normal operating range. Thoroughly check for any oil leakage and clogging.
• Check the condition of the machine to identify the • Fuel system is free from oil leakage, and pipe is
applicable symptom from “List of trouble symp- not damaged or dent.
• Intake system parts for fault.
symptom chart.
• Check with the customer if correct engine oil and • Exhaust system parts for fault.
fuel are used.
Diagnostic aid
Visual check • Fuel quality (use of fuel other than specified)
Careful visual check is required for some symptom pro- • Intake system fault (clogging in filter, intake pipe
cedures. By this inspection, the problem can be cor- fault, etc.)
rected without performing further inspection, and time • EGR control system fault
can be saved. • Exhaust system fault (exhaust pipe fault etc.)
• Engine coolant temperature (ECT) sensor fault
• There is no dirt or clogging in air cleaner element.
• Boost pressure sensor fault (sensor, pipe, etc.)
• Engine body trouble (compression pressure short-
age, related to the piston, turbocharger, rise of oil)

Check the EGR control system.
3 — Go to “EGR control
Is the procedure completed? Go to Step 4. system check”.
Check the reed valve of the EGR.
4 If the trouble is detected, repair as required. —
7 —
repair if faulty.
8 • Valve system (valve clearance) —

9 —

necessary.
Note:
11 —

Replace the ECM.
Note:

13 —
repair if faulty.
• Valve system
14 • Injector —
• Timing gear

15 —
EGR valve check Push the EGR valve with finger to make sure it opens/
completely when the finger is released.
TSWG0150
Noise
Pre-inspection • Pipes and hoses relevant to fuel, air and oil are
check” and check all the following items.
• Check for noise by referring to the machine’s man-
ual.
• ECM and diagnosis lamp operate properly. • Intake system parts for fault.
• Check the DTC.
• Scan tool data shows normal operating range. Diagnostic aid
• Check the condition of the machine to identify the
applicable symptom from the table of contents.
Perform the procedure described in the symptom
chart.
• Check with the customer if correct engine oil and
• Intake system fault (EGR valve fault)
fuel are used.
• Injector fault (no fuel injection)
Visual check • Engine body fault (seizure, compression pressure
shortage, other mechanical trouble)
cedures. By this inspection, the problem can be cor- • Machine side related equipment trouble (oil pres-
rected without performing further inspection, and time sure pump etc.)
can be saved. This inspection includes the following • ECM trouble (body, power supply, ground, etc.)
items. • Check the connector for poor contact, the harness
• Wire is connected, tightened or cut properly. for fault such as wear or bend, and the wire inside
• ECM ground is not contaminated and installed to the harness for loosened wire causing short circuit
the proper position securely. to other circuits. Also, perform the function diagno-
Repair if faulty.

Identify the source of the noise and confirm the
1 noise. — Repair or replace
Is the noise metallic noise? the faulty parts. Go to Step 2.
Perform the pre-injection stop test.
Select the “Stop pre-injection” from the scan tool
3 menu to perform the test. —
Perform “Injection Stop for Each Injector”.
the scan tool menu.
4 —

Note:
service manual.


Check the EGR valve.
• Fault in reed valve
6 • Fault in EGR valve body —

Refer to “Engine section” in the service manual to
check the engine trouble.
7 Repair or replace the faulty part. —


Fuel consumption deteriorates.
Pre-inspection • Wire is connected, tightened or cut properly.
Before using this paragraph, perform the “OBD system • ECM ground is not contaminated and installed to
check” and check all the following items. the proper position securely.
• Fuel consumption varies depending on handling of • Pipes and hoses relevant to fuel, air and oil are
each machine. Check Hitachi Construction free of crack or twist, and are properly connected.
Machinery’s measure of fuel consumption (A). Thoroughly check for any oil leakage and clogging.
Measure of fuel consumption (L {qts}/hour) • Fuel system is free from oil leakage, and pipe is
• Check the actual fuel consumption (B). Actual fuel not damaged or dent.
consumption (L {qts}/hour) • Intake system parts for fault.
• If B is bigger than A, check the machine’s setting • Exhaust system parts for fault.
by referring to the machine’s manual.
• Check if excessive load is applied to the machine. Diagnostic aid
• Refer to the list of inspection and maintenance • Fuel system fault (run out of fuel, frozen fuel, air
items of the operation manual for proper inspection mixed in fuel pipe, faulty filter [clog in main filter,
depending on the operation time. gauze filter], pipe fault, fuel quality, fuel tank [for-
• If the operation time exceeds 3000 hours, inspect eign matter, fuel suction fault])
by referring to the machine’s manual. • Intake system fault (EGR valve fault)
• ECM and diagnosis lamp operate properly. • Injector fault (excessive fuel injection etc.)
• Check the DTC. • Engine body fault (seizure, compression pressure
• Check the condition of the machine to identify the shortage, other mechanical trouble)
applicable symptom from “List of trouble symp- • Machine side related equipment trouble (oil pres-
tom”. Perform the procedure described in the sure pump etc.)
symptom chart. • ECM trouble (body, power supply, ground, etc.)
• Check with the customer if correct engine oil and • Check the connector for poor contact, the harness
fuel are used. for fault such as wear or bend, and the wire inside
• Check if periodic maintenance has been per- the harness for loosened wire causing short circuit
formed for engine oil replacement, air cleaner filter, to other circuits. Also, perform the function diagno-
fuel filter, etc. sis to check the operation and control of each part.
Repair if faulty.
Visual check
cedures. By this inspection, the problem can be cor-
can be saved. This inspection includes the following
items.

1. Compare the measure of fuel consumption
with the actual fuel consumption.
A: Measure of fuel consumption (L {qts}/hour)
B: Actual fuel consumption (L {qts}/hour)
1 2. If B is bigger than A, check the machine’s set- —

ting or if excessive load is applied to the
machine by referring to the machine’s manual.

Check for fuel leakage.
Check if periodic maintenance has been performed
for engine oil replacement, air cleaner filter, fuel fil-
3 ter, etc. — Perform mainte-
nance for the
Is the procedure completed? machine. Go to Step 4.

Check the intake system and intercooler for water
4 accumulation. — Go to “Intake sys-
Check the exhaust system for crush, bent or clog-
5 ging. — Go to “Exhaust sys-
Check for output shortage.
6 — Go to “Output short-
Is the procedure completed? Go to Step 7. age, lag down”.
Check if the engine oil of viscosity mentioned in the
operation manual is used. Replace with the
7 — appropriate oil, and
Is the appropriate oil used? Go to Step 8. Go to Step 1.
Check the cooling fan for fault.
Perform “Injection Stop for Each Injector”.
the scan tool menu.
10 —

Note:
service manual.

Check the engine compression pressure.
Check the valve clearance.
Has the engine operated for more than 3000
hours?
If more than 3000 hours, check or repair the engine
14 friction by referring to “Engine section” in the ser- —
vice manual.

Check the injector using injector checker. Refer to
1E-82, “How to use injector checker, How to
Inspect Injector” in this section for how to use injec-
15 tor checker. —

Inspection location of engine intake/exhaust system
3 1
6 7 8 9 10
TSWG0163
Name
1. Exhaust pipe 6. Secondary EGR cooler
2. To intercooler 7. From intercooler
3. From air cleaner 8. EGR valve
4. EGR duct 9. EGR duct
5. Primary EGR cooler 10. EGR duct
Check the above intake/exhaust system for fault such as clogging, crush or breakage.
Besides the inspection location of engine body, check the air cleaner, intercooler and muffler.
Oil consumption deteriorates.
Pre-inspection Visual check
Before using this paragraph, perform the “OBD system Careful visual check is required for some symptom pro-
check” and check all the following items. cedures. By this inspection, the problem can be cor-
• Oil consumption varies depending on handling of rected without performing further inspection, and time
each machine. Check Hitachi Construction can be saved. This inspection includes the following
Machinery’s measure of oil consumption (A). items.
Measure of oil consumption/hour. Measure of oil • If bluish-white smoke is emitted continuously while
consumption forengine alone: 4 L {4.2 qts}/ 100 engine running.
hours • If blow-by gas is emitted.
• Check the actual oil consumption (B). Actual oil • If oil is mixed in the coolant.
consumption /hour
• Pipes and hoses relevant to oil are free of crack or
• Refer to the list of inspection and maintenance twist, and are properly connected. Thoroughly
items of the operation manual for proper inspection check for any oil leakage and clogging.
depending on the operation time.
• Lubrication system is free from oil leakage, and
• If the operation time exceeds 3000 hours, inspect pipe is not damaged or dent.
by referring to the machine’s manual.
• Intake system parts for fault (turbocharger check).
• Check the DTC. Diagnostic aid
• Check the condition of the machine to identify the • Intake system fault (rise/decline of oil, excessive
applicable symptom from the table of contents. blow-by gas)
Perform the procedure described in the symptom • Engine body fault (oil combustion, excessive blow-
chart. by gas)
• Check with the customer if correct engine oil and Also, perform the function diagnosis to check the oper-
fuel are used. ation and control of each part. Repair if faulty.

Check the following for trouble occurrence:
• Engine speed
• Operational pattern (continuous/intermittent)
• Operating load (mode in use)
• Oil consumption /hour
• If more than 100 hours has elapsed since initial
1 operation. —
Compare with the specified value of oil consump-
tion by referring to the machine’s manual.
Note:
Use the operation mode mentioned in the
machine’s manual to make comparison.
Explain this to the
Is the oil consumption within specified value? customer. Go to Step 2.
Check for oil leakage. Repair or replace the faulty
2 part. —
Check if bluish-white smoke is emitted while engine
running.
3 If it is emitted only at the starting, go to “Exhaust —
gas contains a lot of white smoke.”
Is bluish-white smoke emitted? Go to Step 4. Go to Step 6.

Check the blow-by gas quantity.
4 —
Is it more than the specified value? Go to Step 7. Go to Step 5.
Check for oil leakage from the turbocharger.

Check if oil is mixed in the coolant.
6 —
Is oil mixed in the coolant? Go to Step 10. Go to Step 11.
Check the engine compression pressure.
Check the engine for wear around the piston or
wear of the cylinder liner.
Note:
service manual.

Check for oil decline from the valve stem or oil seal.
Note:
9 service manual. —

Overhaul the water pump.
Note:
service manual.

Check for oil leakage from the engine external/
internal.
11 Note: —
service manual.

Special tool
List of Special Tool Illustration Tool No. / Tool name
Illustration Tool No. / Tool name
Injector checker
5-8840-2691-0
Digital multimeter
IJC
Tech2
Scan tool
5-8840-0632-0
Terminal remover
5-8840-0388-0
Weather pack terminal
remover
5-8840-0385-0
Breaker box
5884003850
Engine module program-

ming system
EMPS
Difference by Each Machine Manufacturer

Hitachi Construction Machinery Co., Ltd.
List of DTC
SPN FMI P Code DTC description Trouble
SPN FMI P Code DTC description Trouble
display
display
on
on
monitor
monitor
652 3 P0202 Open circuit in injec-
1239 1 P0087 No pump pressure
❍ tion nozzle #2 drive ❍
feed (fuel leakage)
system
157 0 P0088 Common rail pressure
❍ 653 3 P0203 Open circuit in injec-
fault (1st stage)
tion nozzle #3 drive ❍
157 0 P0088 Common rail pressure system
❍
fault (2nd stage)
157 2 P0089 Common rail pressure tion nozzle #4 drive ❍
fault (Excessive pres- ❍ system
sure feed in pump)
1347 0 P0090 SCV drive system tion nozzle #5 drive ❍
open circuit, +B short ❍ system
or ground short
108 3 P0107 Barometric pressure tion nozzle #6 drive ❍
sensor fault (low volt- ❍ system
age fault)
190 0 P0219 Overrun ❍
108 4 P0108 Barometric pressure
102 3 P0237 Boost pressure sen-
sensor fault (high volt- ❍
sor fault (low voltage ❍
age fault)
fault)
172 4 P0112 Intake air temperature
102 4 P0238 Boost pressure sen-
sensor fault (low volt- ❍
sor fault (high voltage ❍
age fault)
fault)
172 3 P0113 Intake air temperature
723 2 P0335 Crank sensor fault (no
sensor fault (high volt- ❍ ❍
signal)
age fault)
723 2 P0336 Crank sensor fault
110 4 P0117 Engine coolant tem- ❍
(signal fault)
perature sensor fault ❍
(low voltage fault) 636 2 P0340 Cam sensor fault (no
❍
signal)
110 3 P0118 Engine coolant tem-
perature sensor fault ❍ 636 2 P0341 Cam sensor fault (sig-
❍
(high voltage fault) nal fault)
174 4 P0182 Fuel temperature sen- 10001 3 P0487 EGR position fault
sor fault (low voltage ❍ (Brushless specifica- ❍
fault) tion)
174 3 P0183 Fuel temperature sen- 10002 2 P0488 EGR valve control fault ❍
sor fault (high voltage ❍
100 3 P0522 Engine oil pressure
fault)
157 4 P0192 Common rail pressure age fault)
100 4 P0523 Engine oil pressure
age fault)
157 3 P0193 Common rail pressure age fault)
628 2 P0601 ROM fault ❍
age fault)
10013 2 P0603 EEPROM fault ❍
tion nozzle #1 drive ❍ 1077 2 P0606 CPU monitoring IC
system ❍
fault
10007 2 P0606 CPU fault ❍
SPN FMI P Code DTC description Trouble SPN FMI P Code DTC description Trouble
display display
on on
monitor monitor
10005 1 P0611 Charge circuit fault 10011 2 P1635 Voltage fault in 5-V
❍ ❍
(bank 1) power supply 5
10006 1 P0612 Charge circuit fault 639 2 U2104 CAN Bus fault ❍
❍
(bank 2)
639 3 U2106 CAN timeout fault ❍
987 3 P0650 Check engine lamp
❍
fault How to clear DTC
1240 1 P1093 No pump pressure 1. Connect the harness for memory clear to the data
❍
feed (fuel leakage)
link connector.
633 7 P1095 Pressure limiter open ❍
105 4 P1112 Boost temperature
age fault)
105 3 P1113 Boost temperature
age fault)
110 0 P1173 Overheat ❍
10003 2 P1261 Injection nozzle com-
mon 1 drive system ❍
fault
10004 2 P1262 Injection nozzle com-
mon 2 drive system ❍
fault
91 2 P1271 Accelerator sensor 1-2
❍
comparison fault
TSWG0209
91 3 P1277 Accelerator sensor 1
❍ 2. Turn the key switch to ON.
fault (low voltage fault)
3. Connect the memory clear terminal to the ground
fault (high voltage ❍ for 1 second or more.
fault) 4. Turn the key switch to OFF. (Memory will be
cleared when the key switch is OFF.)
❍
fault (low voltage fault) 5. Disconnect the diagnosis switch terminal.
fault (high voltage ❍
fault)
636 7 P1345 Cam sensor out of
❍
phase
1485 2 P1625 Main relay system fault
❍
(Not enter)
10008 2 P1630 A/D conversion fault ❍
1079 2 P1631 Voltage fault in 5-V
❍
power supply 1
❍
power supply 2
❍
power supply 3
❍
power supply 4
List of DTC that vary depending on the machine manufacturer
On some machines, the diagnosis lamp comes on instead of trouble display monitor on the machine.
4HK1
Recovery
code description detected DTC is set time trouble occurs sis lamp
failure
amount 1
if the speed
decreases
detected. kPa)
Boost pressure
correction/EGR
stopped
detected. kPa)
Boost pressure
correction/EGR
stopped
more. 110°C (230°F). Back-up: come
• DTC P1630, No back-up action on.
P1633, P0117 or
P0118 is not
detected.
more. ously Switch to the
accelerator sensor
input operation
*2, *3: Refer to 1E-284, “List of Diagnostic Trouble Codes” in this section.
6HK1
Recovery
failure
amount 1
if the speed
decreases
Recovery
failure
more. 110°C (230°F) Back-up: come
• DTC P1630, while engine is No back-up action on.
P1633, P0117 or operated.
P0118 is not
detected.
more. ously Switches to the
accelerator sensor
input operation.
*2, *3: Refer to 1E-284, “List of Diagnostic Trouble Codes” in this section.
About wiring diagrams

• There are some sensors which are not connected to the ECM depending on the machine.
• Check the specifications of the machine, since some sensors input/output to ECM via CAN communication.
The areas with screening indicate that are not connected to the ECM.
4HK1
(15A)*
24
107
Engine stop switch CKP sensor
47 106
17
Key switch
80
QOS indicator lamp Engine oil
11 67
Boost temperature lamp 79 pressure sensor
(ON)
7
10 84
Engine coolant
temperature sensor
(50A)*
Glow relay 83
Fuel temperature
sensor
(60A)* Glow plug

99
98 CMP sensor
100
Main relay
Key switch
21 87
40 82
(30A)*
(ST)
90 Common rail
2
101 pressure sensor
5
(10A)*
94 U
93 V EGR valve
92 W position sensor
46
(100A)*
19 Vehicle speed
121
Battery
(10A)*
Fuel pump Injector #1

119
ECM
M
Charge 117 Injector #4
116
Generator
R Injector #3
L 120
E Sterter 118 Injector #2
R S S terminal SCV
B C B terminal 105
113
89
97
42
Accelerator 63 8 Tachometer
position
sensor 64
41
20 18
Barometric 61 37
pressure 71
sensor 60
Intake air
72
temperature
38 7 TOOL
sensor
52 1
Boost Data link connector
95 4
pressure 91 5
sensor 109
Boost
74
temperature
81
sensor
43
U 111 62
EGR valve V
motor M 103 1
W 110
3
Memory clear switch 32 4
TSHK0045
6HK1
(15A)*
24 107 CKP sensor
Engine stop switch 106
47
80
Key switch
17
QOS indicator lamp 67 Engine oil
11 pressure sensor
79
(ON)
Boost temperature lamp

7
84 Engine coolant
10
temperature sensor
(50A)*
Glow relay 83 Fuel temperature

sensor
Glow plug 99
(60A)* CMP sensor
98
100
Main relay 87
Key switch
21
82
40 Common rail
(ST)
(30A)* 90
2 101 pressure sensor
5
(10A)*
94 U EGR valve
93 V position sensor
92 W
46
(100A)*
19 Vehicle speed
121
Injector #1
119
Battery
(10A)*
Fuel pump
114 Injector #2
ECM
M
Charge
117 Injector #3
116
Generator
R
L Injector #4
115
E Sterter Injector #5
120
R S S terminal
B C B terminal Injector #6
118
SCV
105
42 113
Accelerator
position 63 89
sensor 64 97
41
20 8 Tachometer
Barometric 61
pressure 71
sensor 60 18
37
Intake air 72
temperature
sensor
38 7 TOOL
Boost 95
52 1 Data link connector
pressure 91
sensor 109 4
5
Boost 74
temperature 81
sensor
43
U 111 62
EGR valve V 103
M 1
motor W 110
3
Memory clear switch
32 4
TSHK0046
List of items displayed on scan tool
Display item Tech2 display item

Engine torque —
Actual engine speed Engine Speed
Target engine speed Desired Idle Speed
Glow signal Glow Relay
Coolant temperature Engine Coolant Temperature
Engine oil pressure Engine Oil Pressure
Fuel flow —
Barometric pressure Barometric Pressure
Intake air temperature Intake Air Temperature
Boost pressure MAP Sensor
Boost temperature Boost Temperature
Battery voltage Main Relay Voltage
Cumulative used fuel amount —
Tech2 reference value Each machine data is compared with standard value.
The data list is used in trouble diagnosis to judge as out
The data list is used to check the conditions of the
of reference value temporarily or all the time. (This
machine and each equipment.
Tech2 display menu is subject to change without
notice.
4HK1(unoperated P revolution)
Data display item Units Reference value at unoperated P revolution (it var-
ies depending on conditions of the machine.)
System Voltage V 28.7 — 28.8
Main Relay Voltage V 28.3 — 28.5
Desired Idle Speed RPM 500
Engine Speed RPM 1797 — 1801
Accelerator Sensor 1 V 0.0
Accelerator Pedal Position % 0
Difference in Common Rail Pressure MPa —
Common Rail Pressure Sensor V 2.0 — 2.1
Common Rail Pressure F/B Mode Feedback Mode
SCV Duty % Approx. 20 — 53
SCV F/B mA Approx. 750 — 1,350
Engine Coolant Temperature Sensor V 0.4 — 0.5
Engine Coolant Temperature °C 80 — 83
Intake Air Temperature Sensor V 2.4
Intake Air Temperature °C 27
Fuel Temperature Sensor V 1.3
Fuel Temperature °C 44
Barometric Pressure Sensor V 1.9
Barometric Pressure kPa 100
Boost Temperature Sensor V 4.4
Manifold Absolute Pressure kPa 118 — 119
No. 1 Cylinder Fuel Injection Correction Amount mm3/st —
Engine Mode Fuel Mode
EGR Position Difference % —
EGR Motor Duty % 0
EGR Position 1 ON/OFF One of 1, 2, 3 is the reverse polarity.
(e.g. 1=ON, 2=ON, 3=OFF)
(e.g. 1=ON, 2=ON, 3=OFF)
(e.g. 1=ON, 2=ON, 3=OFF)
Starter Switch (On) ON/OFF ON
Starter Switch (ST) ON/OFF OFF
Idle Manual Switch ON/OFF Auto
Idle Up Switch ON/OFF OFF
Idle Down Switch ON/OFF OFF (ON immediately after key switch ON.)
Glow Relay ON/OFF OFF (ON immediately after key switch ON.)
Glow Lamp ON/OFF OFF
Diagnostic Switch ON/OFF ON
Q Adjust Resistance Data 1 — Varies depending on the machine
4HK1 (Two Pump Relief)

Data display item Units Reference value at Two Pump Relief (it varies
depending on conditions of the machine.)
Engine Speed RPM 1,898 — 1,901
SCV F/B mA Approx. 625 — 735
Engine Coolant Temperature Sensor V 0.4
Fuel Temperature °C 43 — 44
Barometric Pressure kPa Approx. 100
Manifold Absolute Pressure kPa Approx. 203 — 210
EGR Motor Duty % 19
(e.g. 1=ON, 2=ON, 3=OFF)
(e.g. 1=ON, 2=ON, 3=OFF)
(e.g. 1=ON, 2=ON, 3=OFF)
6HK1(unoperated P revolution)
Engine Speed RPM 1747 — 1758
Fuel Temperature °C 41 — 42
Barometric Pressure Sensor V 2.6 — 2.8
Barometric Pressure kPa 101
Boost Temperature Sensor V 4.2 — 4.4
EGR Motor Duty % 0
(e.g. 1=ON, 2=ON, 3=OFF)
(e.g. 1=ON, 2=ON, 3=OFF)
(e.g. 1=ON, 2=ON, 3=OFF)
6HK1 (Two Pump Relief)

Engine Speed RPM 1,747 — 1,760
Fuel Temperature °C 41
Barometric Pressure kPa Approx. 101
EGR Motor Duty % 0
(e.g. 1=ON, 2=ON, 3=OFF)
(e.g. 1=ON, 2=ON, 3=OFF)
(e.g. 1=ON, 2=ON, 3=OFF)

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ZX200-3 E Manual 1

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Introduction

This Troubleshooting Manual describes the structure and the troubleshooting of

Hitachi Construction Machinery Co.,Ltd

Engine Manual (2/2)

How to Use This Manual

How to use this manual

Precautions on service work

Procedure of trouble diagnosis

How to use trouble diagnosis-related tool

Engine control system

List of function checks

List of diagnostic trouble codes

List of trouble symptom

Abbreviation Name Meaning and remarks

About colors of wirings

Green (base color)

Symbol Color Symbol Color

Vehicle speed Engine oil pressure

CKP CKP Engine coolant

3 H-6 7 H-20 11 H-20 10 H-20 9 H-20

0.75 0.75 0.75

0.75 B 2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

Precautions on Service Work

Commercial electrical equipment Caution:

Welding work on the machine

Damage caused by electrostatic discharge

• Do not reuse the high-pressure pipe and injector

Procedure of Trouble Diagnosis

Data Link Connector

Read DTC Actuator Test

Step 2 Perform pre-inspection

Step 3 Check service information

Step 4 Check according to each DTC

Step 5 Perform fault inspection for each symptom

2. Middle stage of fault;

Name under a specific condition. A customer’s com-

2. Evaluate the trouble information correctly.

Points for interview

• What Trouble symptom

Check list for engine control system

Fault in related system Diagnosis lamp

t1=approx. 0.3 sec.

Tens digit Units digit

Hundreds digit Tens digit Units digit

If there is no applicable symptom

If there is intermittent (intermittent trouble)

List of final check items

No. Item Purpose Method

Confirmation of powerful electric wave transmitter; if Caution:

Clear with a scan tool

Clear with memory clear switch

About scan tool display

Tech2, KW display CAN display

Data Link Connector

Read DTC Actuator Test

This menu can be used to display the current data.

How to Use Trouble Diagnosis-Related Tool

Softkeys Selection keys (Arrow keys)

• Avoid using and storing it in a place with extreme

• Avoid using and storing it in dusty area. When not

• Avoid using and storing it in a place that it may

Power socket cable (AC/DC adapter)

Check items before use