CMP sensor ‘Vacuum sensor Water temperature sensor Overheat switeh Glow plug Turbocharger control solenoid Boost temperature sensor IMP sensor Supply pump ‘The supply pump highly pressurizes the fuel using the ‘engine torque, and force-feeds the fuel to the common rail, Also, the suction control valve, fuel temperature sensor, feed pump, ete, are installed on the supply pump. Maintenance Information (4JJ1)_15B-35 10, 12 B M4, 15. Boost sensor EGR valve Fuel pressure sensor CKP sensor il pressure sensor uel temperature sensor Suction control valve15B-36 Maintenance Information (4JJ1) Pawezisoois 1. Feed pump 2. Suction control valve 3. Fue! temperature sensor Suction control valve The suction control valve is installed on the supply pump portion, and controls the fuel force-feed to the common til. The ECM controls the fuel discharge amount by regulating the energizing time to the suction control valve. ‘The fuel temperature sensor is installed on the supply ‘pump, and the thermistor changes the resistance value according to the lemperature change. The resistance value becomes lower when the fel temperature is high, and it becomes higher when the fuel temperature is low. The ECM applies 5 V to the fuel temperature sensor through the pull-up resistor, and it calculates the fuel temperature from changes in the voltage and uses it for controlling the supply pump, ete. The voltage becomes lower when the resistance is lower, andit becomes higher whea the resistance is higher. Note + Donot replace the fuel temperature sensor. When an abnormality is found, replace the supply pump assembly ‘Common rail ‘The common rail receives the fuel from the supply pump, retains the fuel pressure and distributes the fuel to each cylinder. The fuel pressure sensor and the pressute limiter are installed on the common rail, 1. Pressure limiter 2. Fuel pressure sensor 3. Common rail Pressure limiter‘The pressure limiter is activated when the pressure inthe ‘common rail becomes abnormally high to release the pressure inside the common rail Maintenance Information (4JJ1)_15 to apply itto the injector, and uses it for fuel injection ‘amount contol and injection timing control by regulating the energizing time of the injector. age) 1, Pressure limiter Fuel pressure sensor ‘The fuel pressure sensor is installed on the eoramon rail, and detects the fuel pressure inside the common rail to convert into the voltage signal and sends it to the ECM, ‘The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is lower. The ECM calculates the actual fuel pressure from the voltage signal sent from the sensor, and uses it to control the fuel injection, etc. 1, Fuel pressure sensor Injector “The injector is installed on the cylinder head portion, and is controlled by the ECM to perform fuel injection. The ECM internally boosts the voltage for driving the injector Engine coolant temperature sensor Engine coolant temperature sensor is installed on the engine block, and the thermistor changes the resistance value according to the temperature change. The resistance value becomes smaller when the engine coolant temperature is high, und ihe value becomes larger when the engine coolant temperature is low. The ECM applies 5 Vito the engine coolant temperature sensor through the pull-up resistor, and calculates the engine coolant femperature from changes in the voltage. This value is used in various control mechanisms, such as for fuel injection control, The voltage becomes higher when the resistance is higher, and it becomes lower when the resistance is Tower. Overheat switel15B-38 Maintenance Information (4JJ1) ‘The overheat switch is installed on the water outlet pipe, and is tumed ON when the engine coolant temperature exceeds 105°C {221° F}. CKP sensor ‘The CKP sensor is installed behind the fuel filter at the left side behind the cylinder block. The sensor rotor is fixed to the crankshaft, with 56 notches arranged st 6° intervals and the section without notch at 30°. This section without notch allows the sensor to generate @ pulse signal by detecting the top dead center of the cylinder No. 1. By detecting the section without notch from the CKP sensor and a single reference protrusion from the CMP sensor, the ECM ean determine the compression top dead center of the eylinder No. 1 and confirm that they are related to each other, CKP sensor Sensor rotor Rotational direction CMP sensor ‘The CMP sensor is installed to the timing chain cover at the tront side of the cylinder head. The CMP sensor detects 5 protrusions per | rotation of the engine to generate a pulse signal. The ECM determines the cylinder and specifies the crank angle using the CMP signal and the CKP signal input from the CKP sensor, and uses the information for the fuel injection control and ealculation of the engine speed. While this control is usually performed using the CKP signal, the CMP signal is used instead when the CKP sensor is faulty. 1, Timing chain sprocket 2. CMP sensor 3, Projection 4, Reference protrusion 5. Rotational direction Oil pressure seusor The oil pressure sensor is installed near the starter motor of the cylinder block, and it detects che pressure of the engine oil to convert into the voltage signal and send it 0 the ECM, ‘The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is lower,Maintenance Information (4JJ1)_15B-39 & = © Panache fp Accelerator position sensor ‘The accelerator position scnsor is installed on the console panel of the machine to supply the voltage signal which varies in accordance with the accelerator volume angle to the FCM, The ECM calculates the accelerator pedal position from the voltege signal, and uses it for fuel injection control and many other controls. Note: As for the installation position of the accelerator position sensor, refer to the manual of the machine, Barometric pressure sensor ‘The barometric pressure sensor is installed on the machine side, and it replaces the barometric pressure with the voltage signal. The ECM calculates the barometric pressure from the voltage signal, and uses the ‘lmospheric pressure to correct the fuel injection amount. Note: + As for the installation position of the atmospheric pressure sensor, refer to the manval of the machine. EGR position sensor TPhis sensor is installed inside the EGR valve to detect the EGR valve lift amount. Note + Donot disassemble the EGR position sensor. When an abnormally is found, replace the EGR valve assembly. Boost sensor ‘The boost sensor detects the boost of the intake manifold to convert into the voltage signal and sends it tothe ECM. The voltage becomes higher whem the pressure is higher, and it becomes lower when the pressure is lower. The ECM caleulates the boost from the voltage signal sent from the sensor, and uses it 10 control the fuel injection, et.158-40 Maintenance Information (4JJ1) = py Be a 1@® ‘The boost temperature sensor The boost temperature sensor is installed to the EGR valve upstream side of the intake manifold. The sensor is the thermistor type, and the resistance value inside the sensor changes in accordance with the change in the temperature. Fuel filter pressure sensor ‘The fuel filter pressure sensor is installed on the fuel filter, and converts the negative pressure inthe fuel filter into the voltage signal, The ECM calculates the negative pressure in the fuel filter based on the voltage signal to determine clogging in the fuel filter. IAT and MAF sensors IAT sensor ‘The IAT sensor is installed on the duct between the ait cleaner and turbocharger. The IAT sensor is variable resistor inside the MAF sensor to measure the temperature of air taken into the engine. When the IAT sensor is cold, the resistance of the sensor is high. When the air temperature rises, the resistance of the sensor becomes low. The ECM detects a high voltage in the sigaal circuit when the sensor resistance is high. For law sensor resistance, the ECM detects a low voltage of the signal circuit ‘MAF sensor ‘The MAF sensor measures the amount of air taken into the engine, and itis installed on the duet between the air cleaner and turbocharger. The MAF sensor consists of the MAF sensor and IAT seusor to measure some of air flowing in the duct. A small amount of air taken into the cengine indicates deceleration or idle speed. A large amount of ait indicates acceleration or high load.Intake throtdle valve ‘The intake throttle valve is installed on the inet of the inlet manifold. The BCM controls the opening angle of | the intake throttle valve according to the condition of ‘engine operation. The motor inside the intake throttle valve is controlled based on the duty ratio signals sent fiom the ECM. The opening angle of the intake throttle valve is adjusted when the duty ratio is changing from 0 % to the appropriate ratio, The valve closes when the uty signal increases, and the valve opens when the duty signal decreases. The opening angle ofthe intake throttle valve is detected by the position sensor. The position ‘sensor ourpats the signal representing the intake throttle valve opening angle. The ECM detects @ low signal voltage when the opening ‘angle is small or the valve is atthe closed position, Also, the ECM detects a high signal voltage when the opening angle is large. Exhaust differential pressure sensor The exhaust differential pressure sensor is installed near DPD. The exhaust differential pressure sensor varies the signal voltage according to changes of the exhaust gas differential pressure between in front and rear of DPD filter. The ECM detects a lower signal voltage when the differential pressure is small due toa small amount of ‘accumulated PM. The ECM detects a higher signal ‘voltage when the differential pressure is large due to a large amount of accumulated PM. ‘The ECM uses this voltage signal for controlling DPD regeneration and determining purification after regeneration. Italso uses the signal voltage to detect filter failures such ‘8.2 too low differential pressure. Maintenance Information (4JJ1)_15B-41 Exhaust gas temperature sensor The exhaust gas temperature sensor is the variable or installed on 2 DPD housings; | atthe front of DPD oxidation catalyst and the other at the front of the filter. The exhaust gas temperature sensor I located bofore the filtor measures exhaust gas temperature before DPD filter, and the exhaust gas temperature sensor 2 located before the oxidation eatalyst measures exhaust 288 tomperature before the oxidation catalyst. When the exhaust gas temperature sensor is cold, the resistance of the sensor is high. When the exheust temperature rises, the resistance ofthe sensor decreases. The ECM detecis a high voltage in the signal circuit when the sensor resistance is high. Also, the ECM detects a low voltage in the signal circuit when the sensor resistance is low. The [ECM uses this voltage signal for temperature control during the DPD regeneration IMT sensor The IMT sensor is a variable resistance installed on the intake manifold to measure the intake temperature of the45B-42 Maintenance Information (4JJ1) take manifold. When the sensor is cold, the sensor resistance is high. When the intake temperature rises, the sensor resistance decreases. For low sensor resistance, the ECM detects a low voltage of the signal circuit, ‘Vacuum sensor ‘The vacuum sensor is installed atthe left side of the cylinder head. The signal voltage varies in accordance with the boost pressure change. The ECM detects a low signal voltage at low boost pressure, and a high signal voltage at high boost pressure. The ECM uses this signal voltage to control the turbocharger eontrol solenoid ‘Turbocharger control solenoid The turbocharger control solenoid is instlled at the left side of the cylinder head. The ECM controls the solenoid valve based on the boost pressure to adjust the negative pressure, The nozzle vane closes further as the negative pressure is higher and opens at no negative pressuie, based on the movement ofthe nozzle control diaphragm of turbocharger. The ECM performs control that changes, the boost pressure by adjusting the nozzle vane opening angle in accordance with the load requirement for the engine, Diagnostic light By tuming ON the diagnostic switch, the DTC is indicated by blinking, Note : As for the installation position of the diagnostic light, refer to the manual of the machine. DLC DLC is the connector for communication and connection between the trouble diagnosis scanning tool and various ‘controllers. 3tallation position, refer to the manual of the machine. Diagnostic switch‘The diagnostic switch shorts DLC terminal No. 12 and. No, 4 or No. and flashes the diagnostic light to indicate the DTC. Note + As for the installation position and shape of the diagnostic switch, refer to the manual of the maghine. Memory clear switch ‘This is used when clearing the recorded DTCs in the ECM by operating the diagnostic switch and the memory clear switeh Note + AS for the installation position of the memory leer switch, refer to the manual of the machine. Mode change switch (0, 1,2) ‘The operation can be performed at the engine speed specified for each mode by switching the mode change switch, Note As for the installation position of the mode change switch, refer to the manual of the machine. Maintenance Information (4JJ1)_ 158-43 Water temperature gauge Oil temperature gauge Hour meter Ignition switch Engine stop switch Fuel meter Memory clear switch Mode switch ECM power distribution diagram Some sensors may not bbe connected to the ECM depending on the specifications ‘ofthe machine, Since some sensors may perform inpuVoutput with the ECM depending on the CAN communication, confirm the specifications of the machine.158-44 Maintenance Information (4JJ1) mie) é (= = aemezon | — yen | ainrapatane pitnoamin | itseemeen | GGOS5S (ices _| Eprom = Doo een apenas atamen -Maintenance Information (4JJ1)_15B-45 ECM pin assignment Geen — a a al a al oof > a @ I 5 c ee @ Meese sntets_F Fe} ete g ren] @ | sonccnan O}-—__—ee J nna Qe samsine i! a 5 ——e— jes a g—_415B-46 Maintenance Information (4JJ1) 94 pns 7% Cl se 2 se il || xe) |e og TT Bra naleseais in rein i pei pa rg osaae7 sea Tas idiahg| |} EIR2_ersesrorirarszarsreripa uw — 415 127 16 Pawan rots 660 pin connectorMaintenance Information (4JJ1)_15B-47 Pin No. Pin name (Connection 1 (OP-COMIA, Injector power source 1, No.1 eylinder 2 ‘OP-COMIB Injector power source 1, No-# eylinder 3 : = 4 7 5 (OM-BBM3, EGR valve DC servo motor drive W 6 SP-SV4 Boost sensor, EGR position sensor, intake throttle position sensor power source: 8 TA-MAT IMT sensor signal 9 TATHL Fuel temperature sensor signal 10, TA-THBST ‘Boost temperature sensor signal TA-PFUEL, TA-OILPRESS Fuel pressure sonsor signal Oil pressure sensor signal 3 eS Tas or peston emo pa 5 OPSCVET Su ave OPO Tic power sore Na Tn 17 OP-COM2B Injector power source 2, No.2 cylinder if : : 2 SPvE CR stor vacuum senor power suse = sa Oi puis onions wae 3 : : = aw Ee ~ scams [PEER tp a 7 SESIDs CP mara 29 - = = aT ana 7 ont a ae 32 a : 3 om Tyan tame ea gine 3a : : 35 ET Tha Dose a = = on waa TTT t Son Ta isae ORF sc hal pessie cw GND 3 sant TP sercr, ons enpertire ses, vacuum sensor OND 3 Sate CP card15B-48 Maintenance Information (4JJ1) B TAScvLO SCV-LO dive 46 OS:INB Injector 3 contol, No eylinder a - : 2 ose Tojesior2 comrol, Nod eyinder OneIDMI Take trot motor drive High 30 ‘ONIDME Tnlake throttle motor drive Low st - ~ 3 TEBMPOSI EGR poston sensor signal U 3 TS-EBMPOS2 TEGR postion sensor signal V 34 TSEBMPOSS EGR postion sesor signal W 55 SG-SVRTS IMT seasor GND 56 TECAM CMP sensor signal 7 T-CRANE CKP sensor signal 3 Ds Tel pressure sensor shield 3 = - By TnScvLo SOLO 94 pin connectorMaintenance Information (4JJ1)_15B-49 Pin No. Pin name (Connection él PG-POWER ECM power source GND. 62 PG-POWER ECM power source GND a PG-POWER ECM power source GND a PG-POWER TECM power source GND. 6 PG-POWER [ECM power soures GND 66 PG-POWER [ECM power source GND 7 en Battery power souroe ob SPSVI “Acceleraior position sensor power source oO SP-SV2 Barometric pressure sensor power source 70 SP-SVS Exhaust differential pressufe sensor, fuel filter pressure sensor power source I : : 2 CER W2000 Data link connector 73 ~ 74 ~ 7 75 : : 76 ~ 77 : : 7 7 “THIEL Exhoust gas temperature sensor 1 signal 80 TATED haus! gas temperature sensor 2 signal 81 TAIAT TAT sensor signal 2 TA-MAF MAF sensor signal 3 TA-FIPRESS Fuel filter pressure sensor signal 84 TA-EXHP Exhaust differential pressure sensor signal 85 TACACCELI ‘Accelerator pedal positon sensor 1 signal %6 TA-AGCEL2 ‘Accelerator pedal position sensor 2 signal 7 IA-BARO, ‘Barometric pressure sensor signal 88 CC-ISOCANT ISO. CAN-Low ® PSB Battery power source 20) SG-SVRT “Agcelerator position sensor GND. 31 : ~ 2 - zi 33, zi z oH zi ~ 35 zi : 96 : : 7 Signal GND 98 - 9 ISSCVSW SCV switch signal 100 ISSTART ignition switch start signal 101 IS-LOAD Toad advance switch signal 102 IS REG Regulation mode switch signal 103 ISAC Air cleuner switch signal 104 ISIDLMNI Ting control change selector switch signal15B-50_ Maintenance Information (4JJ1) 105 = ISMDMAPO Made map switch 0 signal 106 ISIDLUP Tling contvol switch Up signal 107 1S-MDMAPI Mode map switch I signal 108 1S-MDMAP2, ‘Mode map switch 2 signal 108 ISIDLDWN Tiling control switch Down signal 0 CCISOCAN-H TSO CAN-iligh ni PSB Battery power source 12 Exhaust differential pressure sensor, fuel filter pressure sensor, exhaust gas temperature sensor 1, exhaust gas temperature sensor 2 GND 3 MAF sensor GND 14 (OS-MAINR. TECM main relay control ns SG-SEDI ‘Accelerator position sensor shield ne TA-EVRY Lr ‘Vacuum sensor signal 7 SP-12V (MAF sensor power source Ts = i) PG-SIGN Signal GND. 120 : 7 121 IS-ENGSTP Engine stop switch signal 122 IS-DPDREG DPD switch 123 ‘OS-OVRL, Engine overun light 124 (OS-O1LPL Engine oil pressure light 125; (05-BOOSTE, ‘Boost temperature sensor pilot light 126 OS.OVHTL, Overheat light 127 : - 128 OF-TACHO Tachometer 129) ‘OS-DPDREG DPD regeneration ight 130 (OS-DIAGL, Diagnosis Fight BI : : 132 CCCANL CAN-Low 133 PSB Battery power source 134 ISIGKEY, Tgnition switch ON signal 135; SG-SVRT2 Barometric pressure sensor GND. 136 (OS-MAINR. ECM main relay control 7 PG-CASE ECM ease GND 138 ‘OP-EVRV, “Turbocharger contol solenoid drive 139 PS-MAFBAT Dropping resistor 140 - 141 IS-DIAG Diagnostic switch signal 142 1S-MEMCL Memory clear switeh signal 13 IS-DGSEL, Diagnostic switch signal 144 i : 145, ‘OS-GLOWL Glow light 146 : : 147 ‘OS-FIPRESSL Fuel filter clogging lig 148 ‘OST Fuel temperature light 149 OS-DPDSL, DPD lightMaintenance Information (4JJ1)_ 151 150 OS HOUR, Hour meter relay ISL = : 152 (OS-STARTR Slarier cut relay 153 (OS-GLOWR, Glow relay 154 (CC-CAN. CAN-High