TB290 Troubleshooting 4JJ1 de

Introduction
This Troubleshooting Manual describes the structure and the troubleshooting of

electronic control fuel injection system (common rail type) in 4JJ1 industrial engines.
Use this manual sufficiently to perform service work properly and quickly.
Isuzu Motors Limited

Off-highway Powertrain
Operation Dept.
4JJ1 Electronic Control Fuel Injection System (Common Rail Type) 1E-1
Control System
4JJ1 Electronic Control Fuel Injection System
(Common Rail Type)
Table of Contents
How to Use This Manual ....................................... 1E-4 EMPS Operation Procedure..............................1E-104
How to use this manual...................................... 1E-4 1. Preparation.................................................1E-104
Table of abbreviation.......................................... 1E-5 2. ECM Reflash .............................................. 1E-106
Conversion formula ............................................ 1E-6 3. Injector Replacement ................................. 1E-124
About colors of wirings ....................................... 1E-7 4. Replace ECM (Same Model) .....................1E-137
About wiring diagrams........................................ 1E-8 5. Factory Setting ...........................................1E-162
How to read trouble diagnosis section ............... 1E-9 6. Recover Point.............................................1E-173
Precautions on Service Work.............................. 1E-11 7. Error Messages..........................................1E-175
Electrical system .............................................. 1E-11 8. Error Code List ...........................................1E-182
Fuel injection system........................................ 1E-11 How to Use Breaker Box ...................................1E-192
Procedure of Trouble Diagnosis.......................... 1E-13 Breaker box inspection procedure .................1E-192
About trouble diagnosis.................................... 1E-13 Engine Control System .....................................1E-195
Trouble diagnostic procedure........................... 1E-14 Description of function and operation for engine
Interview........................................................... 1E-15 control (common rail) system .........................1E-195
Pre-inspection .................................................. 1E-17 Engine control module (ECM) ........................1E-210
Trouble diagnosis............................................. 1E-17 Engine component location diagram.............. 1E-212
How to read DTC ............................................. 1E-18 Wiring diagram of engine control module (ECM)
Confirmation after repair .................................. 1E-20 .......................................................................1E-225
List of final check items .................................... 1E-20 Pin arrangement of engine control module (ECM)
How to clear DTC............................................. 1E-21 .......................................................................1E-229
Trouble diagnosis with scan tool ...................... 1E-22 Circuit diagram ...............................................1E-240
How to Use Trouble DiagnosisRelated Tool ..... 1E-27 Engine harness location................................. 1E-254
Function of service tools .................................. 1E-27 Connector list .................................................1E-258
Tech2 ............................................................... 1E-27 List of Function Checks .....................................1E-261
Tech2 data reference value ............................. 1E-50 List of function checks....................................1E-261
Rewriting of Q adjust correction data by Tech2 OBD system check.........................................1E-262
......................................................................... 1E-54 Diagnosis lamp illumination circuit system check
Injector ID code (No. 1 cylinder No. 6 cylinder or .......................................................................1E-264
No. 4 cylinder) registration setting using Tech2 Diagnosis lamp blinking circuit system check
......................................................................... 1E-61 .......................................................................1E-266
ID code upload (Tech2).................................... 1E-69 Scan tool power supply circuit system check (Tech2)
ID code download (ECM) ................................. 1E-73 .......................................................................1E-269
TIS2000............................................................ 1E-79 Scan tool power supply circuit system check
How to Inspect Injector........................................ 1E-89 (EMPSIII)........................................................1E-271
Injector balance test (Tech2, EMPSIII) ............ 1E-89 Scan tool communication circuit system check
Trouble Diagnostic Tools (EMPS) for Industrial Engine .......................................................................1E-273
............................................................................ 1E-90 Starting circuit system check..........................1E-276
Introduction ...................................................... 1E-90 Starting system check ....................................1E-281
List of functions of EMPS ................................. 1E-90 Fuel system check .........................................1E-284
Cautions ........................................................... 1E-91 Intake system check.......................................1E-288
EMPS Component Parts .................................. 1E-93 Exhaust system check ...................................1E-288
ECM (hardware) compatibility .......................... 1E-94 EGR control system check.............................1E-289
ECM Variation .................................................. 1E-94 QOS system check ........................................ 1E-292
System Requirements for EMPS Software List of Diagnostic Trouble Codes ......................1E-297
(Recommended) .............................................. 1E-94 List of diagnostic trouble codes......................1E-297
EMPS (software) Setup Procedure .................. 1E-95 DTC: P0087 (Flash code 227) Common rail low
EMPSIII ............................................................... 1E-98 pressure fault (No pressure feed in supply pump)
EMPSIII connection.......................................... 1E-98 .......................................................................1E-313
EMPSIII screen display .................................. 1E-101
1E-2 4JJ1 Electronic Control Fuel Injection System (Common Rail Type)
DTC: P0088 (Flash code 118) Common rail pressure DTC: P0487 (Flash code 44) EGR position sensor
is abnormally high (1st or 2nd stage) ............. 1E-323 fault ................................................................1E-477
DTC: P0089 (Flash code 151) Common rail pressure DTC: P0488 (Flash code 45) EGR valve control fault
fault (Excessive pressure feed in supply pump) .......................................................................1E-483
....................................................................... 1E-329 DTC: P0522 (Flash code 294) Engine oil pressure
DTC: P0090 (Flash code 247) SCV drive system sensor fault (low voltage fault, open circuit, ground
open circuit, +B short or ground short ............ 1E-334 short) ..............................................................1E-489
DTC: P0107 (Flash code 71) Barometric pressure DTC: P0523 (Flash code 294) Engine oil pressure
sensor circuit input is low (open circuit or ground sensor fault (high voltage fault, short to power supply,
short) .............................................................. 1E-340 ground short) ..................................................1E-495
DTC: P0108 (Flash code 71) Barometric pressure DTC: P0601 (Flash code 53) ROM fault ........1E-503
sensor circuit input is high (+5V short) ........... 1E-346 DTC: P0603 (Flash code 54) EEPROM fault
DTC: P0112 (Flash code 22) Intake air temperature .......................................................................1E-505
sensor fault (low voltage fault, GND short, short DTC: P0606 (Flash code 51) CPU fault .........1E-507
circuit)............................................................. 1E-352 DTC: P0606 (Flash code 52) CPU monitoring IC fault
DTC: P0113 (Flash code 22) Intake air temperature .......................................................................1E-509
sensor fault (high voltage fault, open circuit or short to DTC: P0611 (Flash code 34) Charge circuit fault
power supply circuit) ...................................... 1E-358 (bank 1) ..........................................................1E-511
DTC: P0117 (Flash code 23) Engine coolant DTC: P0612 (Flash code 34) Charge circuit fault
temperature sensor fault (low voltage fault, GND (bank 2) ..........................................................1E-514
short, short circuit).......................................... 1E-365 DTC: P0615 (Flash code 19) Starter cut relay circuit
DTC: P0118 (Flash code 23) Engine coolant fault ................................................................1E-517
temperature sensor input is high (open circuit or short DTC: P0650 (Flash code 77) Diagnosis lamp circuit
to power supply)............................................. 1E-371 fault ................................................................1E-522
DTC: P0182 (Flash code 211) Fuel temperature DTC: P1093 (Flash code 227) No pump pressure
sensor fault (low voltage fault, GND short) .... 1E-379 feed ................................................................1E-527
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-385 DTC: P1112 (Flash code 295) Boost temperature
DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, ground short)
sensor fault (low voltage fault, short circuit) ... 1E-393 .......................................................................1E-549
DTC: P0193 (Flash code 245) Common rail pressure DTC: P1113 (Flash code 295) Boost temperature
sensor fault (high voltage fault) ...................... 1E-399 sensor fault (high voltage fault, open circuit, short to
DTC: P0201 (Flash code 271) Open circuit in power supply circuit) ......................................1E-556
injection nozzle #1 drive system .................... 1E-405 DTC: P1173 (Flash code 542) Overheat........1E-563
DTC: P0202 (Flash code 272) Open circuit in DTC: P1225 (Flash code 31) Idle UP/DOWN switch
injection nozzle #2 drive system .................... 1E-410 fault ................................................................1E-569
DTC: P0203 (Flash code 273) Open circuit in DTC: P1261 (Flash code 158) Injection nozzle
injection nozzle #3 drive system .................... 1E-415 common 1 drive system fault .........................1E-573
DTC: P0204 (Flash code 274) Open circuit in DTC: P1262 (Flash code 159) Injection nozzle
injection nozzle #4 drive system .................... 1E-420 common 2 drive system fault .........................1E-580
DTC: P0219 (Flash code 543) Overrun ......... 1E-425 DTC: P1271 (Flash code 24) Accelerator sensor 1-2
DTC: P0237 (Flash code 32) Boost pressure sensor comparison fault.............................................1E-587
fault (low voltage fault, open circuit)............... 1E-427 DTC: P1277 (Flash code 24) Accelerator sensor 1
DTC: P0238 (Flash code 32) Boost pressure sensor fault (low voltage fault) ...................................1E-593
fault (high voltage fault, short to power supply circuit, DTC: P1278 (Flash code 24) Accelerator sensor 1
ground open circuit) ....................................... 1E-434 fault (high voltage fault) ..................................1E-598
DTC: P0335 (Flash code 15) Crank sensor fault (no DTC: P1282 (Flash code 24) Accelerator sensor 2
signal)............................................................. 1E-441 fault (low voltage fault) ...................................1E-603
DTC: P0336 (Flash code 15) Crank sensor fault DTC: P1283 (Flash code 24) Accelerator sensor 2
(signal fault).................................................... 1E-448 fault (high voltage fault) ..................................1E-608
DTC: P0340 (Flash code 14) Cam sensor fault (no DTC: P1345 (Flash code 16) Cam sensor out of
signal)............................................................. 1E-454 phase .............................................................1E-613
DTC: P0341 (Flash code 14) Cam sensor fault DTC: P1625 (Flash code 416) Main relay fault
(signal fault).................................................... 1E-461 .......................................................................1E-618
DTC: P0380 (Flash code 66) Glow relay circuit fault DTC: P1630 (Flash code 36) A/D conversion fault
....................................................................... 1E-467 .......................................................................1E-624
DTC: P0381 (Flash code 67) Glow plug lamp circuit DTC: P1631 (Flash code 55) Voltage fault in 5V
fault ................................................................ 1E-472 power supply 1 ...............................................1E-626
DTC: P1632 (Flash code 55) Voltage fault in 5V
power supply 2 ............................................... 1E-630
power supply 3 ............................................... 1E-634
power supply 4 ............................................... 1E-638
power supply 5 ............................................... 1E-642
DTC: U2104 (Flash code 84) CAN Bus fault.. 1E-646
DTC: U2106 (Flash code 85) CAN timeout fault
....................................................................... 1E-651
List of Trouble Symptom ................................... 1E-656
List of trouble symptom .................................. 1E-656
Engine start failure ......................................... 1E-657
Engine stall..................................................... 1E-665
Engine hunting, rough idling........................... 1E-670
Engine output shortage .................................. 1E-675
Exhaust gas contains a lot of white smoke. ... 1E-679
Exhaust gas contains a lot of black smoke. ... 1E-682
Noise .............................................................. 1E-685
Fuel consumption deteriorates....................... 1E-687
Oil consumption deteriorates. ........................ 1E-690
Special Tool ...................................................... 1E-692
List of special tool........................................... 1E-692
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 Isuzu manuals, start with Precautions on ser-
vice 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
Abbrevia- Name Meaning and remarks

tion
A/D Analog/Digital Analog/Digital
AP Accelerator Position Accelerator opening angle
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 hous-
ing) position
C/U Control/Unit Abbreviation of control unit
CMP Camshaft Position Camshaft (the sensor is installed onto the rear of cylin-
der head) position
DLC Data Link Connector Connector for scan tool (also known as: Checker con-
nector)
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
EMPS Engine Module Programming System Rewriting of control program in ECM
Exh Exhaust Exhaust
F/B Feedback 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
IJC Injector Checker Tester for injector
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 Starting aid system
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
Abbrevia- Name Meaning and remarks

tion
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.)
Conversion formula
Length
km 0.6214 = mile
m 3.281 = ft
mm 0.03937 = in
Pressure
kPa 0.0101972 = kg/cm2
kPa 0.145038 = psi
MPa 10.197162 = kg/cm2
MPa 145.03774 = psi
Tightening torque
Nm 0.101972 = kgm
Nm 0.737562 = lbft
Speed
kg/h 0.6214 = MPH
Temperature
C 1.8 + 32 = F
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 T Tan
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 (MPU) 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. Confirmation 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 specifica-
tions of machines. Confirmation of specifications is
needed.
4. Sections surrounded by heavy lines are used to
differentiate engine harnesses from other har-
nesses. 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.
circuit) 1 2
DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short
3 4 Action taken when DTC is set
Trouble is displayed on the monitor of the
Improper connection of harness connector
Defective harness routing
10
machine* or diagnosis lamp comes on. (* Nothing
is displayed depending on the machine manufac-
Worn harness cladding
Wire disconnection inside harness cladding
turer) Following inspections are necessary to detect these
causes.
Engine control Back-up mode
module (ECM) Improper connection of harness connector and
Rail pressure feedback control stopped
CMP sensor
signal
Common rail pressure
sensor signal
5V
EGR position
sensor signal
EGR position
sensor signal
EGR position
sensor signal
11
Limited injection amount 2 (multi-injection stopped)
ECM connector
Poor connection of terminal from connector
EGR stopped Unmatched terminals are fitted.
B+ B+ B+ Switches the control to SCV compulsory drive Damage of connector lock
80 MPa target Poor contact between terminal and wire
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 Damaged harness
Recovery from failure
Visually check the harness for damage.
Refer to 1E-310, List of Diagnostic Trouble Codes Check the relevant items on the scan tool data
recovery from failure. 12
and About recovery from failure in this section for display while moving the connector and the har-
ness which are related to the sensor. The varia-
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8
tion of the display indicates the faulty part.
4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 The conditions to clear the MIL/DTC
5 The present trouble turns to history trouble when

the condition is out of the range from DTC set con-
Test description
Numbers below indicate step numbers in the chart.
0.75
W/R
0.75
B/W
0.75
Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
dition (recovery from failure). 3. In case of present trouble, the Common rail pres-
W G/Y W/L G/W W/B G/B W/R B
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
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 OFF then ON again. aid .
Br B G W
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-
sure sensor connector is removed, the circuit beyond
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
Diagnostic aid the sensor is normal including ECM.
W
EGR position sensor/EGR motor

U
be the cause. 13
If the intermittent trouble is suspected, followings may
EGR valve
Step Action Value YES NO
CMP sensor Common rail pressure sensor Perform the OBD system check. Perform the OBD
1 system check and
Is the procedure completed? Go to Step 2. Go to Step 2.
TSHK0028 2 Is the scan tool (KW communication) available? Go to Step 3. Go to Step 14.
Check the value for common rail pressure sensor
Description of circuit Main trouble symptom using scan tool.
7
The common rail pressure sensor detects the common Engine stall possible 1. Connect the scan tool.
rail internal pressure. The common rail pressure sensor Output lowering 2. Start the engine.
is installed to the common rail. As the common rail 3 0.7 V (at idle)
3. Check the value for Common rail pressure
internal pressure changes depending on engine condi- Preconditions when DTC is set sensor using scan tool.
tion, output voltage of the common rail pressure sensor
6
will change (if the common rail internal fuel pressure is
low, output voltage becomes low, if the pressure is
8
Key switch input voltage is 18V or more.
DTC P1630 or P1635 is not detected.
Is the Common rail pressure sensor output volt-
age less than the specified value? Go to Step 4.
Go to Diagnostic
aid .
high, the output voltage becomes high as well). The Check for installation condition of the common rail
engine control module (ECM) reads this output voltage DTC set condition pressure sensor, ECM and coupling connector.
change, converting it into common rail internal pres-
sure, to utilize for control. Dedicated communication 0.7V or less.
9
Common rail pressure sensor voltage becomes
4
1.
2.
Check for play or looseness in the connection.
If the trouble is detected, repair or replace as
circuits are used for the sensor power supply (5V), SIG, required.
and ground in the common rail pressure sensor, which
are connected to the ECM. Also, the sensor circuit is Is the trouble detected? Go to Step 12. Go to Step 5.
shielded to avoid electrical noise etc.
Step Action Value YES NO About common rail pressure sensor Breaker box inspection procedure
1. Turn the key switch to OFF . Perform the inspection in the following procedure if
2. Disconnect the common rail pressure sensor there is such an instruction to use breaker box in the
connector. step. After inspection, return to the diagnostic step.
3. Turn the key switch to ON .
5 0V
sensor using scan tool.

age specified value? Go to Step 8. Go to Step 6.
1. Check for followings in the power supply circuit
between ECM and common rail pressure sen-
sor using breaker box or DMM. 3 2 1
Refer to 1E-427, Breaker box inspection pro-
cedure, DTC: P0192 (Flash code 245) Com-
mon rail pressure sensor fault (low voltage
14
fault, short circuit), List of Diagnostic Trouble
Codes .
Note:
If breaker box is not available, refer to 1E-428, TSWG0055
6 On-board check procedure for sensors, DTC: Name
P0192 (Flash code 245) Common rail pressure 1. GND
sensor fault (low voltage fault, short circuit), List of 2. Signal
Diagnostic Trouble Codes . 3. Power supply Name
Open circuit 1. Breaker box
High resistance 2. DMM
Characteristics of common rail pressure
2. If the trouble is detected, repair or replace as
required.
sensor
Is the trouble detected? Go to Step 12. Go to Step 7.

1. Check for followings in the signal circuit
(V)
4.2
sor using breaker box or DMM.
Codes .
Note:
If breaker box is not available, refer to 1E-428,
7 On-board check procedure for sensors, DTC: 1
P0192 (Flash code 245) Common rail pressure
sensor fault (low voltage fault, short circuit), List of
Diagnostic Trouble Codes .
Short circuit to common rail pressure sen-
0 200(29008)
sor ground circuit MPa(psi)
Short circuit to ground TSWG0201
2. If the trouble is detected, repair or replace as

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal
required.
checked method value value
Is the trouble detected? Go to Step 12. Go to Step 9. 6 Open circuit/ Resistance Disconnect the 87 Sensor connector 100 or less 10 M or
Replace the common rail (common rail pressure high resistance measurement sensor connector. power supply terminal more
sensor). Key w
s itch OFF
Note:
8 For work procedure, refer to Engine section ni the
service manual.
TSWG0198
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 while sliding on the seat,
connected to the electrical systems on the machine, sitting down from the standing position, or
such as mobile phones or radios. Therefore, in trouble walking for a certain distance, it is required to
diagnosis of powertrain, first check if this commercial touch the normal grounding before the installa-
electrical equipment is installed, and if so, remove it tion of the parts.
from the machine. If the trouble has not been solved
after the removal, diagnose it in usual procedures.
Fuel injection system
Welding work on the machine Fuel pipe
If performing welding on the machine, remove the bat-
tery in advance. Otherwise, the current during welding
may cause system trouble or damage.
1
Damage caused by electrostatic discharge
The electronic components used in the electronic con- 2
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- 4
trostatic charged. The common way to be charged is 3
caused by friction or induction.
For example, a charging by friction is caused when
a person slides on the seat of the machine. TSJJ0043
Name
1. Injector pipe
2. Common rail
3. Common rail pressure sensor
4. Pressure limiter
Do not reuse the high-pressure pipe and injector
pipe of the fuel system. Replace with new one if it
is removed.
Do not replace the pressure limiter and the com-
mon rail pressure sensor 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
ECM Connector Data Link Connector
Reflash
Data Link Connector
Injector ID Code Read DTC Snapshot Actuator Test
V
V
RPM
RPM
V
V
%
TSJJ0122
Trouble diagnostic procedure
Step 1 Confirm the users 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, customers 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 customers 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-
tomers 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 customers 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 check of engine compartment Basic knowledge for required tools
Visual check of engine compartment should be care- Important:
fully when performing the diagnostic procedure. This If performing the diagnostic procedure, no basic
inspection can often solve the trouble with no extra knowledge on this powertrain may lead to faulty
steps. If performing visual check, follow the guideline diagnosis or damage to powertrain components. If
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 machines
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 machines 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 customers 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-36, Diagnostic procedure, Tech2, How to
Use Trouble DiagnosisRelated 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 technicians 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 customers
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. Items 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 of scan tool Check the engine control and Monitor the scan tool data list and use a typical data
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 checking repair using on-board diagnosis system
the following check items as required. check, perform the following steps. If not following
An antenna should be installed as far away as pos- these steps, unnecessary repair may be needed.
sible from the electrical systems on the machine Review and record the scan tool data related to
such as control unit/sensors. DTC which is diagnosed.
Antenna cords should be installed at least 20 cm Clear the DTC.
(7.8 in) away from the electrical systems on the Operate the machine while checking the rele-
machine such as control units/sensors. vant scan tool data.
Do not put the antenna cords and other wire
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 a memory clear harness (Hitachi
Clear of DTC Construction Machinery Co., Ltd)
1. Connect the harness for memory clear to the data
The DTC, which have been stored in the engine control
link connector.
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, EMPSIII or scan tool with KW
communication) has been connected, it can be cleared
by clear operation of the scan tool (Tech2, EMPSIII 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.
TSWG0209
5. Turn the memory clear switch to OFF.
6. Turn the diagnosis switch to OFF.
3. Connect the memory clear terminal to the ground
7. Turn the key switch to OFF.
for 1 second or more.
8. Leave as it is for 10 seconds.
4. Turn the key switch to OFF. (Memory will be
9. Turn the key switch to ON. cleared when the key switch is OFF.)
10. Turn the diagnosis switch to ON. 5. Disconnect the diagnosis switch terminal.
11. Make sure that memory is cleared.
Clear with ECM (intermittent trouble)
The DTC stored in ECM will be cleared if the same one
is not valid within 20 ignition cycles.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
TSWG0023
Note:
Refer to the machines 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, EMPSIII) and the scan tools
with KW communication can display both the physical
About scan tool value and voltage value.
There are scan tools for each machine manufacturer In some diagnostic charts, both the voltage value and
and the scan tool (Tech2 or EMPSIII) for Isuzu, and physical value may be shown. Refer to the voltage
they have the different display configurations depend- value for Tech2, EMPSIII and the scan tools with KW
ing on communication methods. communication or the physical value for the scan tools
The scan tools for Isuzu (EMPSIII) and the machine with CAN communication.
manufacturer with CAN communication display only the EMPSIII can communicate by both KW communication
physical value in data parameters. and CAN communication.
Value
TSJJ0117 TSWG0182
Name
1. Tech2, EMPSIII and scan tool with KW commu-
nication
2. EMPSIII and scan tool with CAN communication
About scan tool display
Tech2, EMPSIII, 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 Resistance
QR Code (EEPROM) QR code
Starter Switch (On)
Starter Switch (ST)
EGR BLDC Position 1
EGR BLDC Position 2
EGR BLDC Position 3
Glow Relay Switch
Glow Signal
Accelerator Sensor 1 Accelerator Sensor 1
System Voltage
Tech2, EMPSIII, KW display CAN display

Main Relay Voltage
Battery Voltage
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
Request Engine Speed Request Engine Speed
Intake Air Temperature Intake Air Temperature
Boost Pressure
Boost Temperature
Engine Coolant Temperature Engine 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
List of items displayed on scan tool with CAN communication

Sumitomo (S.H.I.) Construction Machinery Manufacturing Co., Ltd.
Items displayed on scan tool with CAN communication Same items displayed on Tech2
Actual engine speed Engine Speed
Target engine speed Desired Idle Speed
Glow signal Glow Relay
Coolant temperature Engine Coolant Temperature
Fuel temperature Fuel Temperature
Engine oil pressure Engine Oil Pressure
Barometric pressure Barometric Pressure
Intake air temperature Intake Air Temperature
Boost pressure MAP Sensor
Boost temperature Boost Temperature
Battery voltage Main Relay Voltage
Hitachi Construction Machinery Co., Ltd.
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
About scan tool (Tech2, EMPSIII)
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 SAE 16/19 adapter.
ECM control
DTC
Sensor output
ECM Connector Data Link Connector
Reflash
Data Link Connector
Injector ID Code Read DTC Snapshot Actuator Test
V
V
RPM
RPM
V
V
%
TSJJ0122
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 DiagnosisRelated Tool

Function of service tools
EMPS EMPSII EMPSIII Tech2 IJC

ECM Reflash
Change Injector QR Code

KW communica-
Data display tion KW communica-
CAN communi- tion
cation
Actuator test

(Injector check)
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 PCMCIA card release button
While operating the Tech2, selection boxes appear on This is used to remove the PCMCIA card from Tech2.
the upper part of the screen. The softkeys correspond Press the button to remove the PCMCIA card. Never
the selection boxes. They cannot be used unless the remove the PCMCIA card when the Tech2 is powered
selection boxes are displayed. on.
Selection keys (Arrow keys) Connector for external communication (RS-232
They are used to select the menu or switch the display port)
on the screen of Tech2. Selected part is highlighted in This is used to connect the Tech2 to a computer.
the screen.
Connector for external communication (RS-485
Action keys (YES, NO, ENTER, EXIT) port)
They are used to execute the operation of Tech2, This is a connector for phone line connection, however
respond to instruction/question, and switch/move to it is not currently used. Do not connect the phone line
each menu screen. etc. to this connector.
Function keys (F0 F9)
They are used to execute a menu function in the Precautions on handling Tech2
screen. These keys also correspond to F numbers, Ventilation
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-
Help key (?) ciently. In badly ventilated area, poisoning may occur
Explanation of Tech2 function, which is being used at due to inhaling colorless, odorless carbon monoxide
the time when the key is pressed, is displayed included exhaust gas.
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
this case, all the keys except selection keys and func- Operating voltage of Tech2 is DC 12 V. Do not
tions are locked. When the power is on, the green LED energize 24 V to it.
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-
nect the DLC cable. TSWG0111
Connector for AC adapter connection

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.
Do not have an impact on it by dropping. It causes Avoid using and storing it in dusty area. When not
internal faults even no damage on appearance. using it, always put it in its case to prevent the
adapter from getting dust.
TSWG0112
Be sure to turn off the power of Tech2 when install- TSWG0114
ing/removing the PCMCIA card. Avoid repetition of Avoid using and storing it in a place with rapid
installing/removing the card as possible. Other- changes of temperature. If bringing it from cold
wise, the card may be deteriorated. outside into warm indoor suddenly, dew condensa-
Before turning on the Tech2, make sure that the tion may occur resulting in malfunction or trouble.
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
TSWG0113
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.
TSWG0117
Power supply
About power supply
TSWG0116
The power supply method for the Tech2 varies depend-
Avoid using and storing it in a place that it may
ing on the voltage of the machine, shape of DLC and
contact water or chemicals. When cleaning, use
the situation in which the unit is used. Therefore the
cloth with mild detergent, not highly-volatile solvent
user will have to gain good understanding of the rele-
such as thinner, and wipe out using dry cloth. Its
vant connecting procedure.
display is easy to get dirty, clean periodically using
Notice that machine data and DTC will not be able to
antistatic cloth.
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.
Power Supply Connection
TSWG0162
Name
1. Battery cable 2. Power socket cable (AC/DC adapter)
Battery cable PCMCIA Card
This cable should be used, in the case where no power Check to see whether the slot (upper side) has this
is supplied even when the Tech2 is connected to the card inserted with its Tech2 label side up.
machine through the machine DLC cable, or where the
machine works with a higher voltage than the operating CAUTION:
voltage of the unit. When connecting the cable, pay If the card is not inserted properly and the unit is
heed to the polarities of the clamps. (The black clip of switched on, NO PCMCIA CARD INSERTED will
the cable is to be connected to the negative terminal of appear. If that is the case, turn off the power and
the battery and the red clip to the positive terminal.) redo the insertion of the PCMCIA Card.
CAUTION: Connection
In the case of a 24-V machine, connect to battery Check to see whether the DLC cable is fitted with an
on the body ground side to take out 12 V. adapter compatible with the machine.
Note:
Before connecting the cable to the machine, verify that
the key switch is in the OFF position.
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.
TSWG0141
CAUTION:
Power socket cable (AC/DC adapter) Connecting method varies depending on each
machine. Refer to the machines manual. The fol-
This is used to check the captured data by operating lowing description is for the machine with DLC.
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
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.
TSWG0118
SYSTEM INITIALIZING
TSHK0144 TSWG0084
6. Turn the ignition switch to ON and press the

PWR key of the Tech2. Display of POST results:
If the test ends normally, Pass will appear and one
7. Check the display of the Tech2. short sound will be heard.
If the test ends abnormally, Fail will appear and three
short sounds will be heard.
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.
Startup
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
(Power-On Self Test) is carried out, and if the test ends
normally, a sound will be issued at the completion of
the test. Simultaneously, the LED of the SHIFT key will TSGW0085
momentarily come on. This is also meant to check the Pass: Normal, Fail: Abnormal
normality of the LED.
Note:
Only for UART, SCI, RTC, and CLKMEM in particular,
the test result may appear as Fail without this mean-
ing any trouble. For Fail above, refer to 1E-49, 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
SCI: Serial Communication Interface
TPU: Time Processor Unit
RTC: Real-Time Clock
CLKMEM: Clock Memory
KEYPAD: Keypad
Press [ENTER]
Main Menu
If all the functions are normal after the Tech2 has been
switched on, the Start Up screen will open, displaying
the Version No. and the applicable model year, stored
on the PCMCIA card, to allow the user to verify the
information. After the Start Up screen has opened,
pressing the [ENTER] key will cause the Main Menu
to appear. The Main Menu offers 4 different applica-
tions to select from. The desired menu can be executed
moving the highlight bar to it with the relevant function
key or selection keys and pressing the [ENTER] key.
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.
Data Display: Shows the input/output data to/from
the machine controller under test. Since the dis-
played data varies from a system to another, and
besides, most of the items do not have their guid-
ance standard values installed, it is necessary to
first check what the displayed data means.
Snapshot: Allows to record and display the data of
malfunctions occurred. The displayed data not only
includes the one corresponding to the moment
when a malfunction occurred, but also those that
existed before and after the occurrence of the mal-
function. It also provides the function (Plot) to draw
graphs.
F1: Service Programming System (SPS) TITLE AREA
Shows the item currently selected.
Note:
Except industrial engine. MESSAGE AREA
Shows a supplementary explanation or instruction.
F2: View Capture Data DISPLAY AREA
Allows to review data recorded under Snapshot of F0: Displays data parameters and values (9 lines 23
Diagnostics. characters).
F3: Tool Options
Offers the function to make settings for the Tech2 main FULL TEXT AREA
unit, to display POST (Power On Self Test) results, and Shows details of the parameter under the highlight bar.
to perform detailed tests (PCB, VCI). SOFT KEY AREA
Tech2 Self Test: Performs troubleshooting on the The softkeys below the function item display boxes are
functions of the main unit. valid.
WARNING:
WHILE THIS FUNCTION IS UNDER EXECUTION, DO
NOT CONNECT 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.
V
V
RPM
RPM
V
V
%
MPa
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 2. Press the function key [F0] or bring the cursor to
1. When the Tech2 is switched on, the software ver- [F0: Diagnostics] on the Main Menu screen by
sion and the model year applicable to the software operating the selection keys (). And then,
will also be shown. Confirm the display and press press the [ENTER] key.
the [ENTER] key.
TSWG0088
TSWG0110
3. Select the Model Year corresponding to the 5. Press the function key [F0] or bring the cursor to
desired diagnostic action on the Vehicle Identifica- [F0: Engine] by operating the selection keys ().
tion screen and press the [ENTER] key. And then, press the [ENTER] key.
TSWG0089 TSWG0091
4. Select the Vehicle Type on the Vehicle Identifica- 6. Select Powertrain (Eng. name) on the Vehicle
tion screen and press the [ENTER] key. Identification screen and press the [ENTER] key.
TSWG0090 TSWG0092
7. The items chosen in steps 3 to 6 are shown in the 9. Once the communication is established, the unit
Message Area display section. If the identification will show the part No. and DDI (Diagnostic Data
of the machine is OK, turn the ignition key ON to Identification) (which varies from a system to
START and press Next by following instructions another). Press the softkey [Confirm] and go on to
given on the screen. the application. If any mistake was made in the
selection of the vehicle type, despite that the com-
Note: munication is enabled, a message to that effect will
If you make any mistake, pressing the [EXIT] key will appear flashing. If that is the case, check the vehi-
return you to the Main Menu. cle type again and redo the operation from step 1.
TSWG0094
TSWG0093
8. The following illustration shows the state in which Pressing [EXIT] key in the steps 3 to 9 will return
the Tech2 is waiting for communication with the you to the Main Menu screen.
machine controller. If the softkey Next is pressed
with the ignition key in OFF, this display will stay DTC check
forever. (State of communication disabled) How- 1. Select F0: Diagnostic Trouble Codes on the
ever, turning the ignition key ON to START in Engine screen.
this condition will place the unit in the waiting state
for communication.
TSWG0095
TSWG0122 F0: Diagnostic Trouble Codes

This function allows the user to analyze the infor-
mation on the Trouble Code related to the system
currently under test.
2. Choosing F0: Diagnostic Trouble Codes, the fol- Data Display
lowing menu is displayed.
1. Select F1: Data Display on the Engine screen.
F0: DTC Display
F1: Data Display
F1: DTC Clear
Displays the information concerning various parts
F0: DTC Display
of the engine and transmission as data on the
Loads and displays the DTC information stored in the screen of the Tech2.
machine controller in a priority order.
F1: DTC Clear
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
TSWG0097
d 2. F1: Choosing Data Display, the engine data is
displayed.
V
V
TSWG0123 RPM
RPM
If DTC stored V
V
%
MPa
TSWG0098
TSWG0096
Softkey functions
If you select the softkey DTC while the Data Display
A maximum of 5 data parameters can be fixed on the
function remains active, DTC will be displayed on the
Data Display screen. The 5 fixed parameters will be
Data Display screen.
retained at the upper part of the screen, even when the
Snapshot can be used while the Data Display function
display is scrolled up or down. To fix parameters, bring
the highlight bar to the desired parameter on the remains active. For this, choose Quick Snapshot.
screen, which appears as you select the softkey Choosing the softkey More allows to use additional
Select Items, and press the [ENTER]. The selected functions.
item can be identified by the asterisk (*) which will be For Quick Snapshot, refer to 1E-40, Snapshot,
placed atop the parameter. Move the highlight bar with Tech2, How to Use Trouble DiagnosisRelated Tool.
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
fixed parameters.
V V
V V
RPM RPM
RPM RPM
V V
V V
% %
MPa MPa
TSWG0099
Snapshot 2. Choosing F2: Snapshot, the following menu is

displayed.
1. Select F2: Snapshot on the Engine screen.
F0: Manual Trigger
F1: Any Code
F2: Single Code
F4: Beginning
F5: Center
F6: End
TSWG0100
Snapshot F5: Center
Snapshot is intended to save information received by This function is commonly utilized, since it saves not
the machine controller during its execution. It provides only the data after Trigger Point, but also those prior to
an effective means to analyze data generated when the that. This selection allows to compare data that existed
machine encounters a trouble. Use of this function before the occurrence of a trouble, those present at the
enables the user to focus on the situation in which the time of occurrence of the trouble, and those after the
trouble took place, without having to view all the data trouble, among themselves.
for suspected malfunctions. The Tech2 is capable of F6: End
holding two different Snapshot data. This ability of stor- Saves only the data prior to Trigger Point. This selec-
ing two different Snapshot data allows to compare tion is useful when it is desired to terminate Snapshot
Good and Bad machine states with each other. Since after the occurrence of a trouble.
these data are saved on a first-in, first-out basis, the
first Snapshot data (of older date/time) stored on the Snapshot data replay
PCMCIA card will be lost as it is overwritten when a 1. Press the softkey [Review Data] on the Snapshot
third data comes in. Therefore, be sure to set the inter- Options screen.
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.
About trigger type:

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-
TSWG0101
rence.
F0: Manual Trigger: 2. Move the highlight bar to the data you want
Pressing the softkey Trigger saves data. replayed, and press the [ENTER] key. The data
F1: Any Code: will be replayed.
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.
F4: Beginning
Starts saving data from Trigger Point, and keeps on
saving it, until the Snapshot recording area is filled up.
This selection is effective when the trouble that consti-
tutes the cause is foreseeable.
TSWG0102
Note: 4. Choosing the softkey Accept changes the display
Flashing Trigger means that data is being recorded. screen and shows a graph after a while.
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
V Plot cancel
RPM To close the graph display screen, press the [ENTER]
V key and you will be returned to the Data Display
V screen.
%
Explanation of Plot data displayed
TSWG0103
2. Bring the highlight bar to the parameter you want A
plotted in a graph, as with Select Items, and

press the [ENTER] key.
3. The selected parameter can be identified by the B
asterisk that appears at its top. No more than 3
parameters can be displayed.
C
TSWG0106
Name
A. Maximum values of selected parameters
B. Minimum values of selected parameters
C. Values of selected parameters at Center Point
(E) in frame
D. Number of frames/time
E. Center point of graph indication
TSWG0104
Select frame
1. Press softkey Select Frame.
RPM
MPa
V
V
RPM
V
V
2
%
TSWG0124
1. Denotes recognition of DTC.

A vertical line appears in abscissa, if there is a TSWG0103
Trouble Code issued in the Snapshot Data loaded. 2. Pressing the softkey Select Frame causes the
When plotting a graph, it is advisable to check for following screen.
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
the display screen.
Move : Allows to view changes of data following
the display screen.
Trigger Frame: Displays a trigger point.
More: Switches the displayed softkeys.
Choose the More on the plot display screen.
Zoom In: Shows the abscissa by enlarging it (each
press doubles the display).
Zoom Out: Shows the abscissa by reducing it TSWG0125
(each press halves the display).
First Frame: First frame No. and data acquisi-
Over View: Shows the entire frame. tion time from Trigger Point (calculated back-
More: Switches the displayed softkeys. ward).
Choose the More on the plot display screen. Last Frame: Last frame No. and data acquisi-
Time / Frame conversion: Switches the value in tion time from Trigger Point (integrated).
abscissa. Go To Frame: Entering a frame No. allows to
More: Switches the displayed softkeys. view its data.
+/: Only the sign is displayed.
3. 1 entered via keys in the Go To Frame area. 3. Select the Common Rail System.
V
V
RPM
RPM
V
V
%
MPa
TSWG0107 TSWG0128
4. Select the Rail Pressure Test.

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
1. Connect the Tech2 to the machine DLC.
2. Start the engine and run it at idle.
TSWG0146
5. Send the instruction to RPCV and check the data 5. Send instruction to each injector (set to OFF by
list. softkey on Tech2 screen) to stop the injector, and
check the variation of engine speed.
RPM
MPa V
V
RPM
RPM
V
V
%
TSWG0147
6. If variation of data list is proper value, RPCV is TSWG0139
judged as normal. 6. If the engine speed varies when the injector stops,
electrical circuit of that injector is judged as normal.
Injector balance test If the engine speed does not vary when the injector
This test is performed to confirm that proper electric stops, electrical circuit of that injector or injector
signal is sent to injector while the engine is running. body is judged as faulty.
Note: Injector control test

At test, the engine is controlled to low idle speed, in This test is performed to confirm that proper electric
order to clarify the variation of engine speed. signal is sent to each injector. The Tech2 must be used
in this test.
Test procedure Test procedure
1. Connect the Tech2 to the machine DLC. 1. Connect the Tech2 to the machine DLC.
2. Start the engine and run it at idle. 2. Turn the key switch to ON (engine is standstill).
3. Select the Common Rail System. 3. Select the Common Rail System.
4. Select Injection Stop for Each Injector. 4. Select Injector Force Drive.
TSWG0138
TSWG0131
5. Send instruction to each injector (set to ON by soft- 4. Select the Glow Plug Relay.
key on Tech2 screen), and check the operation
sound of injector.
V
V
RPM
RPM
V
V
%
TSWG0133
5. Send the instruction to glow plug relay and check

TSWG0132 whether the lamp on the machine operates.
6. If the operation sound is heard, electrical circuit of
that injector is judged as normal.
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.
TSWG0137
4. Select the EGR Control. Sample use of snapshot data replay
1. Turn on the power.
TSWG0140
5. Send the instruction to EGR valve and check the TSWG0110

data list. 2. Press the [ENTER] key.
%
%
%
TSWG0135
TSWG0108
6. If variation of data list is proper value, EGR valve is
3. Choose F2: View Capture Data and press the
judged as normal.
[ENTER] key. View Captured Data appears.
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.
4. Choose Snapshot Data with selection keys () Softkey functions
and press the [ENTER] key. 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
of each frame.
TSWG0109
5. Press the softkey [Continue] on the display screen. 3. Choose More out of the 4 softkeys on the display
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.
screen.
TSWG0126
DTC: Shows the frames in which a Trouble
6. Snapshot Replay Screen appears.
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.
Next DTC-Chg: Shows the frames in which a
V Trouble Code was issued, in the range after the
V displayed frame.
RPM
RPM More: Switches the displayed softkeys.
V 6. Choose More out of the 4 softkeys on the display
V screen.
% The Snapshot Replay screen is restored.
MPa
Difference in operation of Snapshot Data Replay:
The operations of Snapshot Data Replay under F2:
View Captured Data are somewhat different from
those of Replay (softkey function Review Data) under
TSWG0107 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 the
Automatically executes function tests on the Main PCB [ENTER].
and VCI modules. 2. Choose the F2: Set Unit and press the [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 the [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 the
[ENTER].
2. Choose the F1: Set Clock and press the
[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.
TSWG0145
* Metric
Temperature: C Speed: km/h
* English
Temperature: F Speed: MPH
Tech2 data reference value

The data list is used to check the conditions of the machine and each equipment.
Each machine data is compared with standard value. The data list is used in trouble diagnosis to judge as out of ref-
erence value temporarily or all the time. (This Tech2 display menu is subject to change without notice.
Idle speed
Data display item Units Reference value at idle (it varies
depending on conditions of the
machine.)
System Voltage V 28.2 28.6
Main Relay Voltage V 27.7 28.4
Target engine speed RPM 800
Engine Speed RPM 799 801
Accelerator Sensor 1 V 0.0
Accelerator Opening Angle % 0
Difference in Common Rail Pressure MPa 1 0
Common Rail Pressure Sensor V 1.4
Common Rail Pressure F/B Mode Feedback Mode
SCV Duty % Approx. 35 36
SCV F/B mA Approx. 925 980
Engine Coolant Temperature Sensor V 0.6
Engine Coolant Temperature C 70 73
Intake Air Temperature Sensor V 2.1 2.2
Intake Air Temperature C 31
Fuel Temperature Sensor V 1.0 1.1
Fuel Temperature C 5 52
Barometric Pressure Sensor V 1.9
Barometric Pressure kPa 97 99
Boost Temperature Sensor V 3.8 3.9
Boost Temperature C 44 45
MAP Sensor V 1.0
Manifold Absolute Pressure kPa 101
Engine Oil Pressure Sensor V 1.3 1.4
Engine Oil Pressure kPa 216 232
Main Fuel Injection Timing CA 2
No. 1 Cylinder Fuel Injection Correction mm3/st
Amount
Amount
Amount
Data display item Units Reference value at idle (it varies

depending on conditions of the
machine.)
Amount
Engine Mode Fuel Mode
EGR Position Difference % 0
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 OFF
Q Adjust Resistance Data 1 Varies depending on the machine
Engine Start Rotation
Engine Start Rotation (after starter
replacement)
Two Pump Relief

Data display item Units Reference value at Two Pump Relief (it
varies depending on conditions of the
machine.)
System Voltage V 28.1 28.6
Main Relay Voltage V 27.6 28.3
Target engine speed RPM 2212
Engine Speed RPM 2,204 2,208
Accelerator Opening Angle % 100
Difference in Common Rail Pressure MPa 2 0
Common Rail Pressure Sensor V 3.5 3.7
Common Rail Pressure F/B Mode Feedback Mode
SCV Duty % Approx. 21 22
SCV F/B mA Approx. 588 654
machine.)
Engine Coolant Temperature Sensor V 0.4 0.5
Engine Coolant Temperature C 78 83
Intake Air Temperature Sensor V 2.1 2.2
Intake Air Temperature C 31
Fuel Temperature Sensor V 1.1
Fuel Temperature C 50 51
Barometric Pressure Sensor V 1.8 1.9
Barometric Pressure kPa 97 99
Boost Temperature Sensor V 3.8
Boost Temperature C 47 48
MAP Sensor V 3.1 3.2
Manifold Absolute Pressure kPa Approx. 243 244
Engine Oil Pressure Sensor V 2.1 2.8
Engine Oil Pressure kPa 440 536
Main Fuel Injection Timing CA 6
Amount
Amount
Amount
Amount
Engine Mode Fuel Mode
EGR Position Difference % 0
EGR Motor Duty % 17
(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 OFF
machine.)
Engine Start Rotation
Engine Start Rotation (after starter
replacement)
Rewriting of Q adjust correction data by Step 2
Tech2 Choose the menu F0: Diagnostics with , (up/
Q adjust, Injector code label is attached to the cylin- down) keys or F0 (function) key, and press the
der head cover. It is used for rewriting and registering [ENTER] key.
the ID.
1 2 3 4
TSWG0088
TSHK0098
Name Step 3
1. Engine number Choose the menu (5) 2005 with , (up/down)
2. Typical engine model keys, and press the [ENTER] key.
3. Q adjust information * Applicable for 2000MY or later.
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 the [ENTER] key.
TSWG0089
TSWG0110
Step 4 Step 6
Choose the menu (Off-Road) Industrial Engine Choose 6HK1-TC (C/Rail_TIER3) with , (up/
with , (up/down) keys, and press the [ENTER] down) keys, and press the [ENTER] key.
key.
TSWG0092
TSWG0090
Step 7
Step 5 Press the softkey [Next].
Choose F0: Engine in Menu with , (up/down) The ignition is ON at this time.
keys or F0 (function), and press the [ENTER] key.
TSWG0093
TSWG0091
Step 7-1 Step 9
Choose the menu F4: Programming with , (up/
down) keys or F4 (function) key, and press the
[ENTER] key.
TSWG0122
Step 8
TSHK0050
Press the softkey [Confirm].
This displays the ECU ID information. Step 10
Choose the menu F0: Q adjust with , (up/
[ENTER] key.
TSWG0094
TSHK0051
Step 11 Step 12-1
Choose the menu F2: Service mode with , After entering the password, press the [ENTER]
(up/down) keys or F2 (function) key, and press the key.
[ENTER] key. The password for 4/6HK1 and 4JJ1 is SLNPTL4.
F0: Uploads the three-point Q adjust data stored in the The password for 6WG1 and 6UZ1 is SLNPTL6.
ECM to the Tech2. Entering wrong password will return to the previ-
* Registers the data when replacing ECM. ous menu.
F1: Writes the three-point Q adjust data temporarily
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.
TSHK0054
Step 12-2
If the password you have entered is correct, press
the softkey [Okay].
TSHK0052 Enter the password within 120 seconds. Failure to
enter the password within 120 seconds will return
Step 12 to Step 11.
Password input screen
This procedure will end automatically if the regis-
tration is not completed within 120 seconds.
The message Time Over appears.
TSHK0055
Step 13
After completing the password registration, pro-
TSHK0053 ceed to ID registration.
Step 13-1 Step 15
The numbers will appear on the screen. Obtain the ID Displays the three-point Q adjust data in the ECM.
code from the machine manufacturers service center 1. To modify the Q adjust data, press the softkey
or Isuzu Industrial Engine Dept. service section by [Change].
using this number (6855 in this case).
Enter the obtained ID code (2495 in this case). At this
time, the suffix 0 will be added to the end of it on the
Tech2 screen. Press the [ENTER] key.
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 the [ENTER] key.
TSHK0059
Step 15-1
If the Q adjust data you have entered is correct,
press the [ENTER] key.
1. The entry conditions are as follows.
Conditions:
C/Rail system entry setting is 1 15.
TIS system entry setting is 1 8.
TSHK0057
Note:
Step 14 Q adjust information in the label attached to the cylin-
der head cover is given in hexadecimal number. Enter
When the ID code matches, the following screen it into Tech2 in decimal number as below.
will appear.
Press the softkey [Next].
Label information Enter into Tech2
This step can be performed only when the engine
speed is 0 rpm. 1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
A 10
B 11
C 12
D 13
E 14
TSHK0058
Label information Enter into Tech2 Step 15-3

F 15 If the Q adjust data you have entered is off the set
value, the message shown as Step 15-4 appears.
TSHK0101
TSHK0099
Step 15-2 Step 15-4

To go to Step15-5, modify the Q adjust data within
If the Q adjust data you have entered is correct,
the set value and press the softkey [Program].
press the softkey [Program].
TSHK0102
TSHK0100
Step 15-5 Step 16-1
If the entered values meet the conditions in Step If the entered Q adjust data in Step 15-1 does not
15-1 and 15-3, the status display of data registra- correspond to that written in the EEPROM of the
tion (writing) from the Tech2 to ECM as shown ECM, the following message will appear.
below will appear. Pressing the softkey [Done] returns you to Step 11.
TSHK0103 TSHK0105
Step 16
When the writing of data completes, the following
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.
TSHK0104
Injector ID code (No. 1 cylinder No. 6 4/6HK1, 6WG1, 6UZ1
cylinder or No. 4 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
Name
1. Injector ID plate
2. Injector ID code
3. Injector
4JJ1
TSHK0098
Name
1. Engine number
2. Typical engine model
3. Q adjust information
4. Injector information 1
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 strike
through in the illustration, of ID code on the injector ID
plate. (except 4JJ1) TSJJ0131
Name
1. Injector ID code
Refer to the following instruction for how to register

Injector ID code.
Step 1 Step 3
Press the [ENTER] key. Choose the menu (5) 2005 with , (up/down)
keys, and press the [ENTER] key.
TSWG0110
TSWG0089
Step 2
Choose the menu F0: Diagnostics with , (up/ Step 4
down) keys or F0 (function) key, and press the Choose the menu (Off-Road) Industrial Engine
[ENTER] key. with , (up/down) keys, and press the [ENTER]
key.
TSWG0088
TSWG0090
Step 5 Step 7
Choose F0: Engine in Menu with , (up/down) Press the softkey [Next].
keys or F0 (function), and press the [ENTER] key. The ignition is ON at this time.
TSWG0091
TSWG0093
Step 6 Step 7-1

Choose 6HK1-TC (C/Rail_TIER3) with , (up/
down) keys, and press the [ENTER] key.
TSWG0122
TSWG0092
Step 8 Step 10
Press the softkey [Confirm]. Choose the menu F1: Injector ID Code with ,
This displays the ECU ID information. (up/down) keys or F1 (function) key, and press the
[ENTER] key.
TSWG0094
TSHK0108
Step 9
Step 11
down) keys or F4 (function) key, and press the Choose the menu F1: ID Code registration with ,
[ENTER] key. (up/down) keys or F1 (function) key, and press
the [ENTER] key.
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.
TSHK0050
TSHK0067
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
TSHK0069
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- 2. At this point, enter the model code (MC) and ID
der. code (D0) in this order.
Model code (MC) Engine model

55 4HK1
55 6HK1
5A 6WG1 (Varies depending on
the machine)
63 6WG1 (Varies depending on
the machine)
5F 4JJ1
5B 6UZ1
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
TSHK0072 (left/right) keys.
3. Data must be entered within 00 FF.
Step 14 You can enter 0 through 9 with the function
To register the ID code, press the softkey keys (F0 F9), or 0 through Z with , (up/
[Change]. down) keys.
The ID code for Cylinder1 (No. 1 cylinder) selected 4. Enter BCC code.
at Step 13 is shown here. Tech2 calculates the entered data and displays
the following message.
When entered ID code (QR) is off the set value:
Writing unable
When entered BCC code is off the set value:
Writing unable
When the ID code (QR) does not correspond to
BCC code: Writing unable
TSHK0073
TSHK0074
Step 15-1 Step 15-3
After entering the ID code input data byte (MC-D9), If you have entered incorrectly (D7:EG), do the follow-
press the [ENTER] key. ing.
After pressing [ENTER] key as with Step 15-1, press
the softkey [Program]. This cause the error message
Invalid data Please Try again! to appear.
TSHK0075
Step 15-2
If the ID code you have entered is correct, press TSHK0077
the softkey [Program].

If you want to quit the program (registration), press Step 16
the softkey [Abort] or press [EXIT] key. If the entered values meet the conditions in Step
Quitting the registration or pressing [EXIT] key 15-1 and 15-3, the status display of data registra-
returns you to Step 11. tion (writing) from the Tech2 to ECM as shown
below will appear.
TSHK0076
TSHK0078
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 [Done] returns you to Step 11.
TSHK0080
ID code upload (Tech2) Step 3
Step 1 Choose the menu (5) 2005 with , (up/down)
keys, and press the [ENTER] key.
TSWG0089
TSWG0110
Step 4
Step 2
Choose the menu (Off-Road) Industrial Engine
Choose the menu F0: Diagnostics with , (up/
with , (up/down) keys, and press the [ENTER]
key.
[ENTER] key.
TSWG0090
TSWG0088
Step 5 Step 7
Choose F0: Engine in Menu with , (up/down) Press the softkey [Next].
keys or F0 (function), and press the [ENTER] key. The ignition is ON at this time.
TSWG0091
TSWG0093
Step 6 Step 7-1

Choose 6HK1-TC (C/Rail_TIER3) with , (up/
down) keys, and press the [ENTER] key.
TSWG0122
TSWG0092
Step 8 Step 10
Press the softkey [Confirm]. Choose the menu F1: Injector ID Code with ,
This displays the ECU ID information. (up/down) keys or F1 (function) key, and press the
[ENTER] key.
TSWG0094
TSHK0108
Step 9
Step 11
down) keys or F4 (function) key, and press the Choose the menu F2: Upload ID Code (Tech2)
[ENTER] key. with , (up/down) keys or F2 (function) key, and
then press the [ENTER] key.
TSHK0050
TSHK0060
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 ID code download (ECM)
When the ID code registered in the ECM does not Step 1
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.
TSWG0110
Step 2
Choose the menu F0: Diagnostics with , (up/
[ENTER] key.
TSHK0064
Step 12-4
11.
TSWG0088
TSHK0065
Step 3 Step 5
Choose the menu (5) 2005 with , (up/down) Choose F0: Engine in Menu with , (up/down)
keys, and press the [ENTER] key. keys or F0 (function), and press the [ENTER] key.
TSWG0089 TSWG0091
Step 4 Step 6
Choose the menu (Off-Road) Industrial Engine Choose 6HK1-TC (C/Rail_TIER3) with , (up/
with , (up/down) keys, and press the [ENTER] down) keys, and press the [ENTER] key.
key.
TSWG0092
TSWG0090
Step 7 Step 8
Press the softkey [Next]. Press the softkey [Confirm].
The ignition is ON at this time. This displays the ECU ID information.
TSWG0093 TSWG0094
Step 7-1 Step 9

[ENTER] key.
TSWG0122
TSHK0050
Step 10 Step 11-1
Choose the menu F1: Injector ID Code with ,
(up/down) keys or F1 (function) key, and press the
[ENTER] key.
TSHK0089
Step 12
TSHK0108
Press the softkey [Confirm].
Step 11 As an example, the vehicle will be checked
whether it is in the condition (engine stopped) that
Choose the menu F3: Download ID Code (ECM) the ECM requests during ID registration.
with , (up/down) keys or F2 (function) key, and
then press the [ENTER] key.
TSHK0090
TSHK0088
Step 12-1 Step 13
The following display appears while checking if the Pressing the softkey [Yes] downloads (registers)
engine speed is 0 rpm. the uploaded ID codes (Cyl.1-Cyl.6) to the ECM.
When the engine speed is 0 rpm, it will take you to Pressing the softkey [No] returns you to Step 11.
Step 13. Download is the function to register (write) the
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.
TSHK0091
Step 12-2
The following display appears when the engine TSHK0093
speed is not 0 rpm.

In this case, stop the engine as instructed in the Step 13-1
message, and try again from Step 1. Registration is started from No. 1 cylinder (INJ.#1)
to No. 2 cylinder (INJ.#5) and the ECM in the
order.
The status for registration (writing) of data to ECM
will appear.
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.
TSHK0092
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.
11.
TSHK0095
Step 13-3
When the downloaded ID code does not corre-
spond to that registered (written) in the ECM, the
following message will appear.
11.
TSHK0096
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. 5. Select the language to be used, and click the
2. Insert the distribution CD-ROM into the CD-ROM Next.
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.
7. On the Choose serial port for Techline. screen, 9. On the Salesmake screen, select either the
select the serial port of the serial cable to connect Isuzu - General Export (General Export VIN) or
Tech2 to the PC. Isuzu US (US VIN) and click the Next.
Normally, select the COM1 and click the Next. [Example (UBS 6VE1 engine)]
General VIN: JACUBS26GY7100001
US VIN: JACDJ58X3Y7100001
8. On the Set HARDWARE_KEY screen, select the

LPT and click the Next.
10. On the TIS 2000 installation mode, select the
Standalone and click the Next.
11. On the TIS 2000 Update screen, click the OK. This describes about how to transmit and display
Tech2 snapshot data using the Snapshot Upload
function of TIS 2000. Snapshot data can be displayed
with the Snapshot Upload function of TIS 2000. The
trouble symptom can be checked by analyzing snap-
shot data with various methods. To display the snap-
shot data, perform the following 3 steps;
1. Record the snapshot data in Tech2.
2. Transmit the snapshot data to PC.
After recording the snapshot data to Tech2, trans-
mit the data from Tech2 to PC in the following pro-
cedure.
a. Startup TIS 2000.
b. Choose the Snapshot Upload/Display on the
initial screen of TIS 2000.
c. Either select the Upload from diagnostic tool
or click the appropriate icon on the tool bar.
d. Select the Tech2 and transmit the saved
snapshot data.
12. If the installation is completed, the TIS 2000 icon
is displayed on the desktop. e. Select the Transmitted Snapshot.
An error message may appear when restarting f. When the snapshot data transmission is com-
the PC at Step 12. pleted, the data parameter list will appear on
In this case, install the following file in the CD- the screen.
ROM.
~cosidsDiagMdac_type.ex_
Copy this file on your hard disk, change the file
name into mdac.exe, and double-click
mdac.exe.
After this work, install TIS 2000 again.
How to display snapshot
Fig. 2: Data display (sample)

3. Display snapshot data with the Snapshot Upload
function of TIS 2000.
Snapshot data are stored in the PC hard disk or
floppy disk, and they can be displayed any time.
Stored snapshot can be displayed in the following
procedure.
a. Startup TIS 2000.
Fig. 1: Application Selection screen b. Choose the Snapshot Upload/Display on the
initial screen of TIS 2000.
c. Either select the Open file or click the relevant
icon on the tool bar.
d. Select the Transmitted Snapshot.
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 4. After selecting all the parameters (up to 3 parame-

Numeric value and graph (up to 3 for graph display): ters) you wish to view, click the [OK] button.
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.
Fig. 4: Graph Parameters window (sample)

5. Selected parameter is shown in graph form, in the 2. Click the graph icon, and select the parameter you
right hand of the data parameter on the screen. wish to view from the list. Change the graph cate-
gory as required.
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
with the mouse button pressed, and then release Fig. 7: Graph display screen (sample)
the mouse button in the display screen.) New
6. Graph display screen can be moved with the navi-
parameter appears to replace the old one. To view
gation icons.
the graph in full screen, move the cursor to the top
of the screen, and click the screen where the cur- Selects/cancels the parameter.
sor changes to magnifying glass icon. This will dis-
play the graph in full screen. Use of parameter select/cancel function allows to
select particular parameter from the list and to display it
Graph display in one frame (up to 6 for graph dis- instantly. First click the parameter you want to view to
play) mark it, then click Select/Cancel Parameters.
Selected parameter is shown in the upper area of [Lock
1. Click the Six graph icon. This opens Graph
line] on the top of the data list. Other parameters can
Parameters window.
be added in the same procedure. Use of parameter
[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

Directory to save data
Normally data is saved in C:Program
FilescosidsDATA 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 5. Check the selected location on the Select Diag-
nostic Tool for Download screen, and go to next.
Fig. 1: Application Selection screen

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

Injector balance test (Tech2, EMPSIII)
Refer to 1E-45, Injector balance test, Tech2, How to Use Trouble DiagnosisRelated Tool for injector balance test
by Tech2.
Refer to 1E-103, Actuator process screen, EMPSIII screen display, EMPSIII for injector balance test by EMPSIII.
Trouble Diagnostic Tools (EMPS) for Industrial Engine

Introduction
EMPS is set to two types: EMPS and EMPSIII. Only the person with approval based on the usage agreement
with ISUZU can use EMPS.
Especially ECM Reflash of EMPS function needs special user ID and password.
List of functions of EMPS
Diagnostics Function
CAN Diagnostics Trouble Code
Communication
Data Display
Plot Real-time Display
Snapshot Display
Troubleshooting Manual
QR code
Actuator Test Injector Balancing

KW Diagnostics Trouble Code
Communication
Data Display
Plot Real-time Display
Snapshot Display
Troubleshooting Manual
Programming Fuel Delivery Rate
Injector ID Code
Engine Start Counter
Starter Exchange Counter

Engine Type & Serial No.
Clear Fuel Consumption
Actuator Test Common Rail System Rail Pressure Control
ECM Reflash Function Injector Balancing
ECM Reflash Injection Timing
Injector Replacement Multi Injection Stop
Replace ECM Injector Foced Drive
Factory setting Device Control Glow Plug Relay
EGR Control
TSUZ0087
Cautions 6. Avoid using and storing it in a place that it may
contact water or chemicals. When cleaning, use
For your safety, read the following cautions.
cloth with mild detergent, not highly-volatile solvent
1. Always turn the POWER switch of EMPS selector such as thinner, and wipe out using dry cloth.
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.
7. Avoid using and storing it in dusty area. Store it to

avoid dust on the connector etc. when you don't
use.
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.
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 computer 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.
Maker Product name Model JAN code 57.6 k 38.4 k 19.4 k

Arvel USB Serial Cable SRC06-USB 4950190541981
Buffalo USB Serial Converter Cable BHC-US01/GP 4981254134788
Dynex USB PDA/Serial Adapter DX-UBDB9 *
Cable
Elecom USB to Serial Cable UC-SGT 4953103133716
Loas USB RS232C Converter ZUR-101 4967101189217
Cable
Sanwa supply USB RS232C Converter USB-CVRS9 4969887652039 *
*Error may occur depending on the model of personal computer.
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
ECM (hardware) for 6WG1 and 6U is the same.
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.
ECM Variation
ECM for Shipping Service ECM Blank ECM

Calibration data N/A N/A
QR code N/A N/A
Q trim N/A N/A
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 256 MB or more
HDD 20 GB 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 2. Enter the user name and password, and then click
the [Next] button.
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 [Next] but-
ton.
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 [Next]
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.
4. After the user name and password are verified, the 6. This starts the setup, and the following display
following display appears. appears.
Click the [Next] button. To cancel the setup halfway, click the [Cancel] but-
ton.
5. In the following display, confirm the installation

destination and click the [Next] button. 7. Setup completion
To change the installation destination, click the The setup is completed, and the following display
[Browse] button and select the folder you want to appears. Select [Yes, restart the computer now],
install. and then click the [Finish] button.
Note:
You can also select [No, I will restart the 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.
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.
EMPSIII
EMPSIII connection
Component schematic
ECM
5
ECM Diag Terminating DC IN1 DC IN2
Resistor
ON OFF
Engine Module Programming System
ECM PWR
READY ECM PWR EMPS2 EMPS3 ON POWER
OFF
POWER
RS-232C USB FUSE 3A ON OFF
2 3
TSUZ0088
Name
1. ECM connection cable 4. AC/DC adapter cable
2. RS-232C cable 5. Battery cable
3. USB cable 6. Data link connector (CAN communication cable)
Note:
All cables are showed, however, some cables are not used according to the purpose of use. Refer to the follow-
ing paragraph by the purpose.
The power should be used in one of the AC/DC adapter cable, battery cable, and CAN communication cable
depending on the situation.
The battery cable is connected to either 12V or 24V cable depending on the specification of the machine.
EMPSIII diagnostic connection
Diag Terminating
Resistor
ON OFF

Resistor
ON OFF
ECM PWR
OFF
POWER
TSUZ0090
Note:
The power should be used in one of the AC/DC adapter cable, battery cable, and CAN communication cable
depending on the situation.
Terminating resistor switch

When performing CAN communication, turn the switch
to ON if there is not the CAN controller except for ECM.
ECM reflash connection
ECM

Resistor
ON OFF
ECM PWR
OFF
POWER
TSUZ0091
Note:
The power should be used in either the AC/DC adapter cable or battery cable depending on the situation.
EMPSIII screen display
Snapshot screen (Data display)
TSJJ0155
Name
1. DTC code display field 3. Graph display field
2. Data display field
Snapshot can show real time display and reproduce the save data on data display.
The way to save data is saving by manual operation or setting DTC as trigger.
Note:
On saving data by setting DTC as trigger, the range of saving varies according to the setting before.
For 10 minutes after DTC occurs.
For 10 minutes before DTC occurs.
For certain minutes around the time when DTC occurs.
Snapshot screen (DTC code display)
TSJJ0156
When the DTC code occurs, mark will appear above the graph.
TSJJ0157
Clicking the DTC in the DTC code display field will show a trouble diagnosis manual appropriate to the DTC code.
Actuator process screen
2
1
TSJJ0158
Name
1. Injector select check box 4. Change amount display
2. Injector stop button 5. Change amount specify button
3. Current engine speed display 6. Engine speed change button
This process can change engine speed and stop injection in the specified injector.
Change engine speed

Engine speed will change for the amount specified by the change amount specify button from current.
The change amount can be specified by 10 rpm.
Injector stop
Check the injector check box to stop and press the injector stop button. The injector specified for 10 seconds will
stop.
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
Connection Procedure Prepare the AC adapter that matches the rating

1. Turn the POWER SW to OFF. (12V/24V) of the ECM when drawing power with
an AC adapter.
2. Connect the RS-232C cable.
Do not use a battery at the same time when
3. Connect the ECM harness.
drawing power from an AC adapter.
Note: Do not roll up the ECM harness. Data commu-
Do not roll up the harness cord. nication error will result.
Make sure that the POWER switch of EMPS
4. Connect the AC adapter or battery cable. selector is turned to OFF before connecting/
5. Insert the Data CD into the PC. disconnecting the ECM harness. Damage to
EMPS or ECM selector will result.
Removal Procedure
1. Turn the POWER SW to OFF.
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
Select this when trouble code related to ECM is issued
or reflashing ECM to the latest part number as trouble-
shooting manual indicates.
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.
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 2.2.2 OEM Manufacturer Selection Screen
This screen is used for EMPS user authentication. After selecting the OEM manufacturer, click the [OK] to
advance to 2.3 Connection Confirmation Screen.
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 com-
pulsory reflash) boxes, click [Next] to advanced to
2.2.2 OEM Manufacturer Selection Screen.
[Cancel] button.
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-

sage shown below.
2.5 Selection Menu
After selecting the [Select ECM Location], click the
[Next] button.
If response from the selector is normal, advance to 2.5

Selection Menu.
One of the following messages will appear if any abnor-
mality is discovered. Click the [Return to User Authenti- Selection Item Descriptions
cation screen] button, and check the user ID. To
Items Settings/Operation Performed
continue the process as is, click the [Continue process]
button. Process Menu The process selected in 2.1 Startup
will appear.
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.
If a communication error occurs, advance to the 6.

Recover Point screen.
2.5.1 External Power Confirmation Screen 2.5.2 Voltage Confirmation Screen
This screen prompts for confirmation of an external This screen prompts for confirmation of proper voltage.
power supply.
Clicking the [Yes] button on the power supply voltage

Clicking the [Yes] button on the external power confir- confirmation screen advances to 2.6 Selection Items
mation screen advances to 2.6 Selection Items Confir- Confirmation Screen.
mation Screen. If the power supply voltage cannot be confirmed, click
If an external power supply cannot be connected, click the [No] button to return to 2.5 Selection Menu.
the [No] button 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.
2.6 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.)
2.9 New ECM Parts Number Search Screen
This screen is used to select the search conditions for
Parts Number.
Choose the option from [ENGINE MODEL] and
[ENGINE TYPE], and then click the [Select] button.
Next, choose option from the [OEM NAME], and click
the [Next] button.
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
discovered. Refer to 7. Error Messages.
2.8 Current ECM Parts Number Confirmation

Screen
This screen displays the current ECM parts number.
Clicking the [Next] button advances to 2.9 New ECM
Parts Number Search Screen. Selection Item Descriptions
To cancel former ECM parts number confirmation, click Items Settings/Operation Performed
the [Cancel] button.
ENGINE MODEL Select the engine model that corre-
sponds to the current ECM parts num-
ber.
In the case of enforced update, you
can select all engine models.
ENGINE TYPE Select the engine type that corre-
sponds to the current ECM parts num-
ber.
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
Search Result Confirmation Screen.
A message will appear if an error is discovered by the 2.11 Reflashing ECM Parts Number
check that is performed when the [Next] button is Confirmation Screen
clicked.
This screen displays the reflashing ECM parts number.
After checking the contents, click the [Next] button to
2.10 New ECM Parts Number Search Result perform a CD check and advance to 2.12 Switch Con-
Confirmation Screen firmation Screen 3.
This screen displays the search results. To return to 2.9 New ECM Parts Number Search
After checking the contents, click the [Next] button to Screen, click the [Back] button.
advance to 2.11 Reflashing ECM Parts Number Con-
firmation Screen.
If the search results do not show the parts number you
want, select the NEW ECM PARTS NUMBER INPUT
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 advances 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.)
2.17 Switch Confirmation Screen 6
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.
DATA SELECT switch: WRITE

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 advances 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
Select this when rewriting the injector specific code
(QR code) as replacing due to malfunction of the injec-
tor etc.
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.

screen shown below.
Battery Connection 3.2.2 OEM Manufacturer Selection Screen
After selecting the OEM manufacturer, click the [OK] to

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

This screen is used for EMPS user authentication.
3.2.1 User Authentication Screen (Normal)

[Cancel] button.
tion.
conversion cable.
Panel].
ware].
WindowsXP
Battery Connection
Windows2000

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

nected.

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

Selection Menu.
will appear.
tion Screen.
tion Screen.

power supply.

shown below.
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.


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 2. Enter the injector QR code.

1. Select or enter Cylinder No.
3. Enter the BCC.
After entering, [Check] button will become active.
5. Click the [Set] button.

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

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

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-
ter it into the ECM.
button.
The following confirmation message will appear.
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 [Yes] 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.

firmation Screen.
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)
Upload data (ECM part number and injector QR code)
from currently connected ECM to the personal com-
puter, and select this when downloading data after con-
necting another ECM. This function is mainly used in
emergency.
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 Proce-
dure 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.
4.2.2 OEM Manufacturer Selection 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.

After checking to make sure that the initial settings of
[Next] button.

5. On [Device Manager], select [Ports (COM & LPT)].
WindowsXP
ton.
Windows2000

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

Selection Menu.
will appear.
tion Screen.
tion Screen.

power supply.

shown below.
up to this point.
tion Screen 2.
Selection Menu.


button.
sage shown below.
If response from the selector is normal, perform

uploading QR data.
Parts Number.
the [Next] button.
To return to 4.8 Current ECM Parts Number Confirma-
tion Screen, click the [Back] button.
If the upload is successful, advance to 4.8 Current

ECM Parts Number Confirmation Screen.

Screen
Clicking the [Next] button advances to 4.9 New ECM
Parts Number Search Screen. Selection Item Descriptions
To cancel former ECM parts number confirmation, click Items Settings/Operation Performed
the [Cancel] button.
sponds to the current ECM parts
number.
number.
box.
ENGINE MODEL and ENGINE
TYPE.
ENGINE NUMBER Engine Serial Number uploaded at
startup is displayed.
change.

Next button Performs a check and then advances
to 4.10 Switch Confirmation Screen
3.
A message will appear if an error is discovered by the

check that is performed when the [Next] button is
clicked.

After connecting other ECM, click the [OK] button.

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

Connecting ECM) and Reflash Mode Selection


button.
After configuring the power switch setting, clicking the

[Next] button displays the message shown below.
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.
the [Next] button is clicked.
Selected Option Settings/Operation Performed
Normal Update Advances to 4.12.1 User Authentica-
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].
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.
4.12 User Authentication Screen 4.12.2 OEM Manufacturer Selection Screen
This screen is used for EMPS user authentication. After selecting the OEM manufacturer, click the [OK] to
For [Normal] or [Campaign]
fields, click the [Next] button to advance to 4.12.2
OEM Manufacturer Selection Screen.
[Cancel] button.
4.13 Connection Confirmation Screen

For [Compulsory Reflash]

After entering information in the [ID], [PASSWORD],
and Enforce Update PASSWORD (Password for com-
pulsory reflash) boxes, click [Next] to advanced to
4.12.2 OEM Manufacturer Selection Screen.
[Cancel] button.
Battery Connection 4.14 Switch Confirmation Screen 4
After checking to make sure that the initial settings of
[Next] button.

transmission bit rate (Bit/sec), click the [Next] button to
advance to 4.14 Switch Confirmation Screen 4.
Selection Item Descriptions Turn on the power switch, and then click the [Next] but-
Items Description ton.

rate
exiting the tool.
One of the error messages will appear if an error is dis-


sage shown below.
4.15 Selection Menu
[Next] button.
If response from the selector is normal, advance to

4.15 Selection Menu.
will appear.
tion Screen.
tion Screen.

power supply.

mation screen advances to 4.16 Selection Items Con- Confirmation Screen.
firmation Screen. If the power supply voltage cannot be confirmed, click
shown below.
up to this point.
tion Screen 5.
To change the settings, click the [Back] to return to
4.15 Selection Menu.


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.)
Parts Number.
the [Next] button.
To return to 4.18 Current ECM Parts Number Confir-
mation Screen, click the [Back] button.
If response from the selector is normal, advance to

Screen.

Screen
Clicking the [Next] button advances to 4.19 New ECM Selection Item Descriptions
Parts Number Search Screen. Items Settings/Operation Performed
To cancel former ECM parts number confirmation, click
the [Cancel] button. sponds to the current ECM parts
number.
number.
box.
ENGINE MODEL and ENGINE
TYPE.
ENGINE NUMBER Engine Serial Number uploaded at
startup is displayed.
change.
Items Settings/Operation Performed 4.21 Switch Confirmation Screen 6

Next button Performs a check and then advances The switch confirmation screen is shown below.
to 4.20 ECM Replacement / Data
Confirmation.
A message will appear if an error is discovered by the

check that is performed when the [Next] button is
clicked.
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.


button.
This will start data confirmation, display the message
shown below, and advance to 4.22 Switch Confirma-
tion Screen 7.

Cancel Performs termination, and quits EMPS pro-
gram.
Back Returns to 4.19 New ECM Parts Number
Search Screen.
Next Advances to 4.21 Switch Confirmation
Screen 6.
DATA SELECT switch: WRITE DATA SELECT switch: WRITE

ECM POWER switch: OFF ECM POWER switch: ON
button. This will advance to 4.23 READY LED Confir- button.
mation Screen 1. This will start data confirmation, display the message
shown below, and advance to 4.25 Reflashing Execu-
4.23 READY LED Confirmation Screen 1 tion Confirmation Screen.
The selector LED confirmation screen is shown below.
return to 4.20 ECM Replacement / Data Confirmation.
4.25 Reflashing Execution Confirmation
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.
Click the [Yes] button to return to 4.25 Reflashing Exe-

cution Confirmation Screen.
Click the [No] button to advance to 6. Recover Point.
This starts reflashing and displays the message shown

below.
After reflashing is complete, advance to 4.26 Switch
Confirmation Screen 9.
Note:
One of the messages shown below will appear if an
error occurs during reflashing. (Refer to 8. Error Code
List.)
DATA SELECT switch: WRITE DATA SELECT switch: READ

ECM POWER switch: OFF ECM POWER switch: OFF
button. button.
This will start data confirmation, display the message This will start communication with the selector and
shown below, and advance to 4.27 Switch Confirma- advance to 4.28 READY LED Confirmation Screen 2.
tion Screen 10. A message will appear if an error occurs during com-
munication. Refer to 7. Error Messages.
4.28 READY LED Confirmation Screen 2 4.29 Switch Confirmation Screen 11
The selector LED confirmation screen is shown below. The switch confirmation screen is shown below.
return to 4.27 Switch Confirmation Screen 10.


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.
4.30 Reflashing Result Confirmation Screen 4.31 Engine Serial Number Confirm
This screen displays the parts number reflash result. Engine Serial Number of ECM prior to changing con-
nection will be displayed.

below. After confirming the displayed content, click the [Next]
button to start downloading Engine Serial Number, and
the following display appears.
Check the content and click the [OK] button.

This advances to 4.31 Engine Serial Number Confirm
screen. After download, the Result Confirmation Screen
appears.
Confirm the displayed content and click the [OK] button After download, the confirmation screen appears.
to advance to 4.32 Injector QR Code Change Confir-
mation Screen screen.
4.32 Injector QR Code Change Confirmation

Screen
QR code uploaded from ECM prior to changing con-
nection will be displayed.
Click the [Next] button to advance to 4.33. Result Con-

firmation Screen.
Clicking the [Next] button starts to download the injec-

tor QR code.
4.33. Result Confirmation Screen 4.34 Switch Confirmation Screen 12
This screen displays the result of reflashing. The switch confirmation screen is shown below.
Clicking the [OK] button advances to 4.34 Switch Con- Configure the switch settings as shown below.
firmation Screen 12.

button.

firmation Screen.
4.35 Cable Removal Confirmation Screen 4.36 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.

Battery Connection dure.

5. Factory Setting
Select this when writing the factory setting data (serial
number, injector QR code) to ECM, which does not
contain factory setting engine data such as Service
ECM.
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.
5.2.2 OEM Manufacturer Selection Screen

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

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

nected.

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

Selection Menu.
will appear.
tion Screen.
tion Screen.

power supply.

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 [Yes] 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.

firmation Screen.
5.14 Memory Clear
Perform memory clear in accordance with the instruc-
tions that are displayed.

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 fol-
failed. low 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:
Take care with the following items when connect-
ing the adapter harness to breaker box. Failure to 2
connect may damage the ECM.
Connect the connector on adapter harness
side to the connector of breaker box with the
same No. each other.
When the connecting the connector, align the
cutouts of connector and breaker box each 3
other.
TSWG0051
Name
1. Connector No. (Adapter harness)
2. Connector No. (Breaker box)
3. Cutout
Example of use for breaker box
1. Inspection and measurement of voltage
2 3
Accelerator position sensor
Engine coolant temperature sensor
Intake air temperature sensor etc.
4
2
TSHK0184
Name
1. Breaker box
2. ECM
1
3. Injector
4. Short to the terminal and measure two har-
TSWG0052 nesses at the same time.
Name
1. Breaker box 3. Inspection and measurement with oscilloscope
2. ECM Vehicle speed sensor signal
3. Digital multimeter Crankshaft position sensor signal
Camshaft position sensor signal etc.
2. Inspection and measurement of resistance
Crankshaft position sensor
Camshaft position sensor 3
SCV etc.
TSWG0054
1 Name
1. Breaker box
2. ECM
TSWG0053 3. Oscilloscope
Name
1. Breaker box
CAUTION:
2. ECM
During inspection and measurement, interference
3. Digital multimeter
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 control system
The engine control system is electronic control system The engine control system also has the following sys-
which maintains optimum combustion status of engine tem control functions other than engine control.
all the time according to operating conditions. It con- QOS (Quick On Start) system
sists of the following components.
Engine speed signal output
Electronic control fuel injection system (Common
Self-diagnosis function
rail type)
CAN (Controller Area Network) communication
EGR (Exhaust gas recirculation)
(SAE J1939/21, SAE J1939/11)
Idle speed control
System control schematic diagram

(*: Specifications vary depending on each machine. Refer to the machines 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
Injector coil
SCV
Injector
Supply pump
Fuel tank
TSHK0001
About fuel injection correction About high-altitude correction
ECM calculates the basic injection amount based on ECM calculates the current altitude based on the baro-
the signals from accelerator position sensor, boost metric pressure sensor signal.
pressure sensor, CKP sensor, CMP sensor, etc. It reg- It corrects the optimum fuel flow according to the alti-
ulates the opening/closing period of SCV or electric tude etc. at this time.
conduction of injector according to the common rail
pressure, engine coolant temperature, etc. at this time,
to correct the optimum injection timing and injection
amount.
About starting Q adjust

ECM performs starting Q adjust when the engine
Fuel flow limit (mm 3/st)

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
speed that system can recognize, since it does not rec-
ognize engine rotation.
Engine speed (rpm)
Barometric pressure kPa(psi)

highland
TSWG0173
Control during overheat

550
Starting Q threshold enginespeed In overheating, ECM begins to limit fuel flow when the
engine coolant temperature exceeds 100C (212F),
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 120C (248F)*. (* Set-
60
Minimum firing engine speed ting varies depending on the machine manufacturer)
The system raises an alarm from 105C (221F) for
30
System realization engine speed 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.
TSWG0175
100 (212 )
100%
Fuel fiow
Warning (248 )
indication
DTC set
110
(221 ) (230 )
Engine coolant temperature
TSHK177
Table of Input/Output
Injection control output

Sensor input
PCV (Pressure control valve)
Crankshaft position sensor
TWV (Injector) 1-4
CMP sensor
Fuel temperature sensor
Engine coolant temperature sensor
Barometric pressure sensor
Boost pressure sensor
Actuator control output
Accelerator position sensor 1, 2
EGR DC motor
Vehicle speed sensor
Oil pressure sensor
Boost temperature sensor
Intake air temperature sensor
ECM Relay, lamp control output

Glow relay
Starter cut relay
Switch input Diagnosis lamp
Key switch (ON/Start) QOS indicator lamp
Diagnostic switch Oil pressure lamp
Idling control selector switch Boost pressure lamp
Idling control switch (UP/DOWN)
EGR position sensor
Mode map switch 0, 1, 2
Memory clear switch
Engine stop switch
Communication
Starter relay
Speed signal (output to tachometer)
Regulation mode switch
Tech 2 signal
Road advance switch
CAN (ECU on machine side)
TSJJ0119
Electronic control fuel injection system (Common rail type)

The engine control module (ECM) gets information, such as engine speed, engine load, etc. (signals from various
sensors), and sends electrical signals, based on the information, to the supply pump, injector, etc. in order to prop-
erly control the fuel injection amount, injection timing, etc. in each cylinder.
Injection amount control
Accelerator
Pedal
Position Basic
Fuel Injection
Quantitiy
Final Fuel Injection
Engine Injector ON Time
Reduction Rate Fuel Injection Quantity
Speed Determination
Quantity Correction
Maximum
Fuel Injection
Quantity
Cylinder by Cylinder
Boost Press.
Crrection
Coolant Temp.
Barometric Press.
TSHK0172
The system controls the injector, mainly based on the signals from engine speed and accelerator opening angle or
the designated speed of machine control unit, to maintain the optimum injection amount.
Injection pressure control
The system controls the injection pressure by controlling fuel pressure in common rail. It calculates the appropriate
pressure in common rail on the basis of engine speed, fuel injection amount, etc., and discharges the proper amount
of fuel by operating supply pump resulting in pressure feed to common rail.
Injection timing control
This is substitute for a timer function. The system calculates the fuel injection timing on the basis of mainly engine
speed, injection amount, etc. and controls the injector.
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.
Maximum fuel injection amount
Maximum fuel injection amount is the fuel injection amount calculated according to adjustment of injection amount at
starting by coolant temperature, control of maximum injection amount by boost pressure, control of fuel injection
amount at high altitudes by barometric pressure, etc.
Correction between cylinders
This is not used for this engine.
System schematic diagram
Common rail Pressure

pressure sensor Common rail limiter
Electromagnetic Fuel filter

pump
Supply pump
Pre filter
Injector
Fuel tank
Each sensor
Accelerator, Boost pressure,
Engine coolant temperature, etc.
CMP sensor CKP sensor
TSJJ0102
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.
3
1
4
5
TSJJ0103
Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic pump 7. Injector
4. Pre-filter
Bleed air from fuel system
*1
Electromagnetic Fuel filter

pump
Pre Fuel filter
Supply pump
Fuel tank
TSHK0178
1. Place an appropriate tray under the air bleeder EGR (Exhaust gas recirculation)
plug.
Exhaust Gas Recirculation system is abbreviated to
2. Turn the key switch to ON, and activate the elec- EGR system. It recirculates part of exhaust gas into
tromagnetic pump. (on the machine with electro- intake manifold to mix an inert gas with intake air. This
magnetic pump*1) leads to lower the combustion temperature to limit
3. Loosen the air bleeder plug of the fuel filter ade- emissions of nitrogen oxide (NOx).
quately and operate the priming pump more than It controls amount of EGR by opening/closing the EGR
20 times until the fuel overflows near the plug. valve installed between exhaust manifold and intake
4. Tighten the plug, and operate the priming pump manifold. It determines amount of EGR, based on the
more than 10 times until it is filled with fuel. engine speed and load rate on engine (fuel injection
After waiting for approximately one minute, loosen amount), and operates the EGR valve to control the
the plug and bleed out the air in the fuel filter. (This amount of EGR.
must be repeated a minimum of three times until The cooling system (EGR cooler) equipped on the
no more air comes out from the plug.) EGR gas passage allows to cool down high tempera-
ture EGR gas and mix it with new air to lower the com-
5. Tighten each plug firmly and wipe the spilled fuel
bustion temperature further, resulting in limiting NOx
on the surrounding area. Operate the priming
effectively (Cooled EGR).
pump (10 to 15 times) till it is filled with fuel and
then send fuel to the engine.
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 50%.
Accelerator position
No idle EGR
Engine speed
TSJJ0159
EGR system schematic diagram
Outlet port of coolant Inlet port of coolant

EGR cooler
EGR valve
EGR valve position sensor

Exhaust

Intake air
Intake air temperature sensor
Engine speed
ECT sensor
Engine load
TSJJ0153
EGR and turbine noise
Some engines generate high-frequency sound caused
by the turbine revolution. A silencer can be installed to
absorb the high-frequency sound. Some OEMs may
not apply the specifications (silencer) of countermea-
sure to absorb high-frequency sound in the case that it
is not used in residential area. Therefore, some engine
generate high-frequency sound. High-frequency sound
may be less during the EGR operation, and it may
return to the usual level after the operation stops.
Without EGR
B L LM S I H
TSHK0148
There are two types of control methods described

With EGR below if the regulation mode switch input is provided in
addition to the mode map switch.
Directed speed
TSJJ0154
Engine operation control

There are four types of operation control instructions
described below. These selections vary depending on
each specification.
1. Voltage input by APS (1 4 V)
2. Control by CAN communication
Instruction for accelerator opening angle (0
100%)
Instruction for engine speed B L S H
TSHK0149
3. Control by mode map switch
Instruction for engine speed
Instruction for engine speed and instruction for
variation by APS
4. Instruction for increase and decrease in each
speed by idling switch
Mode map switch

The mode map switch has six speed control modes [H,
S, L, B, I, LM].
Revolution setting is; H > S > L > B > I > LM.
H, S, L and B can be decreased by the APS, but
I and LM cannot.
Directed speed
B L S H
TSHK0150
H, S, L and B in the mode map switch vary by
input from the APS as described below.
EMPS MCX
Shift
ECM LCD TCM
Control
TSHK0153
B L S H If the machine has CAN controller
TSHK0151
Description of mode map switch and each mode
EMPS MCX
rpm
2000 H
H
1800 S
S
1500 L
L
Shift
ECM TCM
1200 Control
B
B
1000
TSHK0154
1V 4V
APS Control by mode map switch
TSHK0152
APS can change the engine speed from each mode ECM
point to the lower speed.
42
Specified engine speeds H, S, L and B are deter- Accelerator
position 63
mined by ECM calibration. sensor 64
41
20
CAN communication
If the machine has no CAN controller Engine stop switch
24
47
Idling selector switch
29
Idle up switch
30
Idle down switch
31
Mode map switch 0
49
Mode map switch 1
50
Mode map switch 2
51
Reguration mode switch
33
Load advance switch
45
TSHK0155
Operation mode External switch Control

MAP0 MAP1 MAP2
H OFF OFF OFF Basic operation
OFF ON ON
ON ON ON
S ON OFF OFF Maximum speed control
#1
L OFF ON OFF Maximum speed control
#2
I OFF OFF ON Constant speed operation
#1
B ON ON OFF Maximum speed control
#3
LM ON OFF ON Constant speed operation
#2
I, LM, H modes H, S, L, B modes (pump for irrigation)
ECM
rpm
Regulation mode switch
33 2000
1000
1V 4V APS
2200 rpm
1500 rpm 2000 rpm

LM I H
Idle speed Max. speed B L S H
Idle speed Max. speed
TSHK0156 TSHK0158
H, S, L, B modes Accelerator position switch
ECM
rpm
2000
42
Accelerator
position 63
1000 sensor 64
41
1V 4V APS 20
100%
1500 rpm 2000 rpm

0%
B L S H
Idle speed Max. speed
TSHK0157 0.2V 1V 4V
TSHK0159
The output voltage varies between 1 V and 4 V when Idling control
the accelerator position switch is operated. Voltage
At warm-up operation, using the Idling control selector
between 0.2 and 1.05 V is recognized as 1 V. Error
switch allows to control the lowest idling speed. Also,
occurs if the voltage is lower than 0.2 V or more than
using the Idling control selector switch allows to auto-
1.05 V.
matically set the lowest idling speed to the optimum
DTC P1271 is detected if the electric potentials on the value according to engine coolant temperature.
ECM terminals No.63 and 64 are not the same.
Note:
Accelerator position switch (APS learning con-
Since specifications vary depending on each machine.
trolled)
Available functions also vary.
Idling control selector switch

Using the Idling control selector switch allows to
switch the idling control function.
100%
(2) Idling control switch

Using the Idling control switch allows to control the
0% idling speed.
Note:
Refer to the machines manual for the locations of idling
(1)
control selector switch and idling control switch.
0%
The highest speed varies depending on engine model,
machine specifications and warm-up condition of
engine.
0.2V 1V 4V
2V
UP
TSHK0160 While pressing the UP side of switch, the engine
speed increases, resulting in increasing the idling
If APS learning control is performed, for example, the speed.
control range will change from 2 V to 4 V (2) because
the 2-V condition is recognized as 0% of opening angle DOWN
by accelerator position learning when the ignition cycle
While pressing the DOWN side of switch, the engine
ends with accelerator position in the 2-V condition (1).
speed decreases, resulting in decreasing the idling
Regulation mode switch speed. However, the idling speed does not decrease
below the lowest speed.
If the regulation mode switch input is provided, the
engine speed varies as described below. Note:
Because the engine speed controlled by idling control
Reguration mode switch
switch is not stored in the ECM when the key switch is
ECM
turned to OFF, next time the engine can be operated at
33
the default speed.
ON
B L S H
TSHK0168
Idle manual control
ON
IGN
SW
ECM
OFF
ON
Manual mode switch
29
Manual mode Idle up switch

OFF
30
SW ON
Idle down switch
31
Idle UP
OFF
SW ON
Idle DOWN
OFF
SW
Engine speed Idle
0 rpm
TSHK0161
Speed limit control

Speed limit control means that the engine control module (ECM) controls fuel injection amount, based on vehicle
speed signal and engine speed, so that the machine speed does not exceed the setting value.
The vehicle speed signal is sent from vehicle speed sensor to pulse matching box. The pulse matching box 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.
Key ON
switch
and
Engine
run OFF
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.
Engine speed output to tachometer (In case of using the signal from ECM)
The engine control module (ECM) outputs the engine speed pulse (4 pulses per engine revolution) as a tachometer
output to tachometer. Tachometer shows the engine speed using the engine speed pulse sent from ECM.
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
Engine speed output to tachometer (In case Tacho sensor specifications
not using the signal from ECM) Output voltage: 2.5V
A tacho sensor is installed onto flywheel housing for Clearance: 1mm+00.2
some machines. In this case, tachometer output from Resistance between signal and ground: 2.30.2k
the tacho sensor is directly sent to the tachometer with- (25C {77F})
out going via ECM.
Tacho sensor
Tachometer output
Signal (Y)
GND (B)
Tachometer
TSJJ0163
TSJJ0162
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 temperature 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
TSJJ0104
Engine control module (ECM) Electrically erasable programmable read only
About functions of ECM memory (EEPROM)
EEPROM has programs which is necessary for ECM to
Note:
control the operation of powertrain and information for
Refer to the machines manual for the locations of ECM.
calibration.
If fault is found in the EEPROM, replace the ECM.
Examples of programs to control powertrain and infor-
mation for calibration in ECM are the following items.
Engine model
Engine number
ECM part number
DTC
Learning value for interval correction of cylinders
QR
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.
TSWG0008
If performing welding on the machine, disconnect
The ECM monitors the information sent from various the battery cable from the negative terminal
sensors all the time and controls each system of the beforehand.
powertrain. The ECM performs the diagnostic function
of the system, detects operational problems of the sys- The ECM is designed to sustain normal consumption of
tem, gives a warning through diagnosis lamp to a driver current relating to the operation of the machine. Cir-
and stores DTC (diagnostic trouble code). The area cuits should not be overloaded. In case of testing of
where the trouble occurred can be identified by the open and short circuits, the circuits of the ECM must
DTC to assist a mechanic to perform repair work. not be connected to the ground or be supplied with volt-
The ECM sends the voltage of 5 V to supply the power age except that there is such an instruction. Be sure to
to various sensors or switches. The ECM controls the use a digital multi-meter (5-8840-2691-0) when per-
output circuits by controlling the ground or power sup- forming the tests of these circuits.
ply circuit through a certain device.
Removal of ECM
ECM and components 1. Turn the key switch to OFF.
The ECM is designed to maintain the level of emission 2. Disconnect the battery cable from negative termi-
as the emission control regulations and get a good per- nal.
formance and fuel efficiency at the same time. The 3. Remove the parts (relay etc.) around the ECM to
ECM monitors various functions of the engine through facilitate removal of it.
the sensors such as crankshaft position (CKP) sensor
4. Disconnect the ECM connector from ECM. (81-pin,
etc.
40-pin connectors)
ECM voltage 5. Loosen the installing bolts (nuts) and remove the
ECM.
The ECM energizes standard voltage to various
switches and sensors. The resistance value of the Note:
ECM is quite high so that the ECM can energize a volt- Installation method and locations vary depending on
age like this. The voltage actually applied to the circuit each machine. Refer to the machines manual.
is low, and it does not sometimes comes on even if the
test light is connected to the circuits. The voltmeter Installation of ECM
usually used in a service shop may not indicate a cor-
rect reading because the input impedance is too low. A Install the ECM in the reverse order of removal.
digital multi-meter which has an input impedance of 10 EGR valve position learning is required after replacing
M (e.g. 5-8840-2691-0) should be used to get an cor- the ECM.
rect reading of the voltage. 1. Turn the key switch to ON.
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.
Key switch
ON
Key switch
OFF
10 sec
TSWG0176
Engine component location diagram
(Component location, its form and parts to be used vary depending on each machine.)
13 12 11 10 9
8
1
7
2 6
5
4
TSJJ0123
Name
1. Engine coolant temperature (ECT) sensor 8. EGR valve
2. Suction control valve (SCV) 9. Boost pressure sensor
3. Fuel temperature (FT) sensor 10. Boost temperature sensor
4. Engine oil pressure sensor 11. Glow plug
5. CKP sensor 12. Overheating switch
6. Common rail pressure sensor 13. CMP sensor
7. Injector
Supply pump The SCV (suction control valve) is installed onto supply
pump section and controls pressure feed of fuel (dis-
charge amount) to common rail. The engine control
module (ECM) regulates period of electric conduction
of SCV to regulate the fuel discharge amount.
3
1
2
TSJJ0105
Name
1. SCV
2. Fuel temperature (FT) sensor
TSJJ0001
3. Feed pump
SCV Replacement procedure
The supply pump pressurizes fuel using engine output, Note:
and pressure-feeds fuel to common rail. Supply pump The illustration indicates the supply pump unit only in
has also SCV (suction control valve), fuel temperature order to explain easily.
(FT) sensor and feed pump.
Note:
For work procedure, refer to Engine section in the ser-
vice manual.
SCV (suction control valve)
SCV
TSJJ0142
1. Disconnect the SCV connector.
TSJJ0106
Name
1. SCV
2. Wash the outside of the SCV using a cleaning 4. Pull out the SCV.
spray.
TSJJ0145
TSJJ0143
Note:
Note: If it is hard to pull it out due to the resistance on the
Wash the SCV to remove dust or foreign matter in O-ring, pull it out while rotating it from side to side.
the pump housing or on the installation surface To prevent foreign matter from entering, do not put
when replacing it. gloves on from the next work.
Do not allow cleaning solvent of the spray to enter
inside of the SCV connector. 5. Remove the O-ring of the SCV.
3. Remove the two bolts which tighten the SCV. Note:

Be careful not to let foreign matter enter the pump
housing at removal.
TSJJ0144
TSJJ0146
6. Check the replacement part. 9. Insert the SCV into the pump housing.
Note:
Insert the SCV by hand until it contacts the housing.
If it is hard to insert the SCV, insert it while rotating it
from side to side slightly.
TSJJ0147
Note:
Make sure that you have got all parts indicated in the
illustration.
7. Place the new O-ring in the O-ring groove. TSJJ0149

10. Tighten the two SCV installing bolts temporarily.
Note:
Do not touch the O-ring with dirty hands. Note:
Perform this work after making sure there is no for- Temporarily tighten the two bolts evenly by hand until
eign matter in the O-ring groove. the SCV contacts the pump housing completely.
TSJJ0148 TSJJ0150
8. After placing the O-ring, apply oil to it.
Note:
Use clean oil such as new engine oil.
Do not let foreign matter on the O-ring.
Fuel temperature (FT) sensor
TSJJ0151
11. Fully tighten the SCV installing bolts to the speci- TSWG0011
fied torque.
The fuel temperature (FT) sensor is installed onto the
Tightening torque:
supply pump, and the thermistor changes the resis-
6.9 10.8 Nm (0.7 kgm/5.1 lbft)
tance according to the temperature. The resistance is
Note: low when the fuel temperature is high, and is high when
After tightening the two bolts, tighten again the bolt the temperature is low. The engine control module
tightened firstly. (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.
TSJJ0152
12. Connect the SCV connector.
13. Wipe off the fuel which was leaked at replacement
work.
14. Start the engine, and make sure there is no fuel
leaked from the installation part of the SCV.
TSJJ0005
Common rail The pressure limiter operates to release the pressure in
common rail when the pressure becomes extremely
high.
Removal
Do not replace the pressure limiter.
If it is damaged, replace it as common rail ASM.
3 2
1
TSJJ0107
Name
1. Common rail
2. Common rail pressure sensor 1
3 2
3. Pressure limiter
The common rail receives fuel from supply pump, holds

the common rail (fuel) pressure and distributes fuel to
each cylinder. The common rail has common rail pres- TSJJ0107
sure sensor, flow damper and pressure limiter. Name

1. Common rail
Note: 2. Common rail pressure sensor
For work procedure, refer to Engine section in the ser- 3. Pressure limiter
vice manual.
The common rail pressure sensor is installed onto com-
Pressure limiter
mon rail, detects fuel pressure in common rail, converts
the pressure into the voltage signal and sends it to
engine control module (ECM). Voltage becomes higher
as pressure becomes higher, and lower as one does
lower. ECM calculates the actual common rail pressure
(fuel pressure) based on the voltage signal sent from
sensors and uses it for fuel injection control etc.
3 2
1
TSJJ0107
Name
1. Common rail
2. Common rail pressure sensor
3. Pressure limiter
Removal Engine coolant temperature (ECT) sensor
Do not replace the common rail pressure sensor.
If it is damaged, replace it as common rail ASM.
TSWG0017
The engine coolant temperature (ECT) sensor is

TSJJ0002
installed onto cylinder head, and the thermistor
Injector changes the resistance according to the temperature.
Resistance 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
calculates 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
(temperature is low), the voltage becomes high.
Removal
Disconnect the connector and remove it with
19mm-wrench
TSJJ0108
The injector is installed onto cylinder head section and

is controlled by engine control module (ECM) to inject 19mm
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
amount and injection timing.
Note:
For work procedure, refer to Engine section in the ser-
vice manual.
TSJJ0010
Installation Crankshaft position (CKP) sensor
Apply Loctite 262 before installing it.
Tightening torque:
20 Nm {2.0kgm/15lbft}
Overheating switch
TSJJ0132
The crankshaft position (CKP) sensor is installed onto

the engine block and generates CKP signal when con-
vex portion of the rotor installed to the crankshaft
passes the sensor. The engine control module (ECM)
TSJJ0136 distinguishes the cylinders by the CMP signal input
from CMP sensor, determines the crank angle and
The overheating switch is installed on the water outlet uses it to control fuel injection and calculate the engine
pipe, and it is turned ON when the engine coolant tem- speed. These controls are performed, usually based on
perature exceeds 105C (221F). CKP signal. However it is done, based on CMP signal if
the CKP sensor is faulty.
Removal
Loosen the nut using an 8-mm wrench to remove Removal
the harness, and remove the sensor using a 21- Disconnect the connector, and remove the 10mm-
mm wrench. mounting bolt and sensor.
21mm
8mm
10mm
TSJJ0128 TSJJ0012
Installation Installation
Tightening torque Tightening torque:
Sensor: 27 34 Nm {2.8 3.5 kgm/20 25 lbft} 5Nm {0.5kgm/44lbin}
Nut: 0.8 1.0 Nm {0.08 0.10 kgm/7.1 8.9 lbin}
Camshaft position (CMP) sensor Installation
Tightening torque:
5Nm {0.5kgm/44lbin}
Engine oil pressure sensor
TSJJ0132
The camshaft position sensor is installed onto the font

of cylinder head and produces the CMP signal when
the cam portion of camshaft passes the sensor. The
engine control module (ECM) distinguishes the cylin- TSWG0067
ders by the CMP signal input from CMP sensor, deter-

The engine oil pressure sensor is installed near the
mines the crank angle and uses it to control fuel
starter motor of the cylinder block; it detects engine oil
injection and calculate the engine speed. These con-
pressure, converts the pressure into the voltage signal
trols are performed, usually based on CKP signal.
and sends it to engine control module (ECM). Voltage
However it is done, based on CMP signal if the CKP
becomes higher as pressure becomes higher, and
sensor is faulty.
lower as one does lower.
Removal
Removal
Scissors gear is installed to the cam gear of 4JJ1
Disconnect the connector and remove it with
engine. When the cam gear has been removed,
27mm-wrench
ensure that the scissors gear is installed properly.
Disconnect the connector, and remove the 10mm-
mounting bolt and sensor.
27mm
10mm
TSJJ0003
Installation
TSJJ0011
Tightening torque:
40 Nm {4.1kgm/30lbft}
Accelerator position (AP) sensor Intake air temperature (IAT) sensor
The accelerator position (AP) sensor is installed onto
machine console panel and supplies the voltage signal,
which changes according to the accelerator volume
angle, to engine control module (ECM). The ECM cal-
culates accelerator position by voltage signal and use it
for various controls such as fuel injection amount con-
trol.
Note:
Refer to the machines manual for the location of accel-
erator position sensor.
Barometric pressure sensor
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 Nm {1.1 1.7 kgm/96 144 lbin}
Note:
Refer to the machines manual for the location of intake
air temperature (IAT) sensor.
EGR position sensor

TSWG0020
The barometric pressure sensor is installed onto the 1

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 machines manual for the location of baro-
metric pressure sensor.
2
TSJJ0125
Name
1. EGR position sensor
2. EGR valve
It is installed in EGR valve and detects the valve lift

amount of EGR.
Note: Removal
Do not disassemble the EGR position sensor. If it is Disconnect the connector, and remove the 10mm-
faulty, replace it as EGR valve ASM. bracket-mounting bolt and sensor.
Removal
Disconnect the connector, and remove the six 12
mm-mounting bolts, nut and EGR valve ASM.
10mm
TSJJ0014
Installation
Tightening torque:
TSJJ0009
10 Nm {1.0kgm/89lbin}
Installation
Tightening torque:
27N m {2.8kgm/20lbin}
The boost temperature sensor is installed onto the

EGR valve upstream side of intake manifold. The sen-
sor is thermistor type. The resistance in the sensor
changes as the temperature changes.
The boost pressure sensor detects boost (intake air
pressure) of intake manifold, then converts pressure
into voltage signal and sends it to engine control mod-
ule (ECM). Voltage becomes higher as pressure
becomes higher, and lower as one does lower. ECM
calculates the boost (intake air pressure) 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 Disconnect the connector and remove it with
19mm-wrench 22mm-wrench.
19mm
22mm
TSJJ0013 TSJJ0161
Installation Installation
Tightening torque: Tightening torque:
10.8 16.3 Nm {1.1 1.7 kgm/96 144 lbin} 24 34 Nm {2.5 3.5 kgm/18 25 lbft}
Tacho sensor Diagnosis lamp

It indicates DTC by blinking after the diagnosis switch is
turned to ON.
Note:
Refer to the machines manual for the locations of diag-
nosis lamp.
DLC (data link connector)
1 2 3 4 5 6 7 8
TSJJ0164 9 10 11 12 13 14 15 16
A tacho sensor is installed onto flywheel housing for

some machines. Tachometer output from the tacho
sensor is directly sent to the tachometer without going
via ECM.
TSWG0023
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 machines manual for the locations of DLC.
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 machines manual for the locations and
form of diagnosis switch.
Memory clear switch

The diagnosis switch and memory clear switch are
used to clear the DTC stored in ECM.
Note:
memory clear switch.
Mode selector switch (0, 1, 2)

The mode selector switch allows to operate at the
engine speed set by each mode.
Note:
mode selector switch.
Mode selector switch
TSJJ0109
Wiring diagram of engine control module (ECM)
There are some sensors which are not connected to the ECM depending on specifications of 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.
(15A)*
24 80
Engine stop switch 67 Engine oil
Key switch 47 pressure sensor
(50A)*
(ON) 79
29
Idle up switch 84 Engine coolant
30
Idle down switch temperature sensor
31
Mode map switch 0
49 83 Fuel temperature
Mode map switch 1 sensor
50
Mode map switch 2
51
Reguration mode switch 87
33
98 CMP sensor
Load advance switch
45 101
Diagnostic lamp 100
6
Engine oil pressure lamp
17 82
QOS indicator lamp Common rail
90
11 pressure sensor
Boost temperature lamp
7
94 U EGR valve
10 93 V position sensor
(60A)*
92 W
Glow relay
(100A)*
111 U
Glow plug V EGR valve
(10A)* 103 M
46 motor
W
Key switch 110
Battery
(ST) Starter relay
19 Vehicle speed
Starter cut sensor
relay
Starter
ECM
121
14
Injector #1
119
Over heat lamp
15 Injector #3
117
Over run lamp
88
116
Main relay 5
(30A)* Injector #2
2 120
40
Injector #4
118
21
SCV
105
113
42
Accelerator 89
position 63
97
sensor 64
41
20 8 Tachometer
Barometric 61
pressure 71
sensor 60 18
37
Intake air 72
temperature
sensor 6
14
Boost 95
38 7 TOOL
pressure 91
sensor 109 52 1
4 Data link connector
Boost 74 5
temperature
sensor 43
62
1
CKP sensor 107
108 3
4
Memory clear switch
32 81
TSJJ0139
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.
(15A)*
24 80
(50A)*
(ON) 79
29
30
31
Mode map switch 0
50
Mode map switch 2
51
33 98 CMP sensor
Load advance switch 101
45
Diagnostic lamp 100
6
Engine oil pressure lamp 82
17 Common rail
QOS indicator lamp 90
11 pressure sensor
7
94 U EGR valve
(60A)*
92 W
Glow relay
(100A)*
111 U
(10A)* 103 M
46 motor
W
Key switch 110
Battery
(ST) Starter relay
19 Vehicle speed
Starter cut sensor
relay
Starter
ECM
121
14
Injector #1
119
Over heat lamp
15 Injector #3
117
Over run lamp
88
116
Main relay 5
(30A)* Injector #2
2 120
40
Injector #4
118
21
SCV
105
113
42
Accelerator 89
position 63
97
sensor 64
41
20 8 Tachometer
Barometric 61
pressure 71
sensor 60 18
37
Intake air 72
temperature
sensor 6
14
Boost 95
38 7 TOOL
pressure 91
sensor 109 52 1
Boost 74 5
temperature
sensor 43
62
1
CKP sensor 107
108 3
4
Memory clear switch
32 81
TSJJ0019
Sakai Heavy Industries, Ltd.
There are some sensors which are not connected to the ECM depending on the machine.
(15A)*
24 80
(50A)*
(ON) 79
29
30
31
Mode map switch 0
50
Mode map switch 2
51
33 98 CMP sensor
Load advance switch 101
45
Diagnostic lamp 100
6
Engine oil pressure lamp
17 82
QOS indicator lamp Common rail
11 90
pressure sensor
7
94 U EGR valve
(60A)*
92 W
Glow relay
(100A)*
111 U
(10A)* 103 M
46 motor
W
Key switch 110
Battery
(ST) Starter relay
19 Vehicle speed
Starter cut sensor
relay
Starter
ECM
121
14
Injector #1
119
Over heat lamp
15 Injector #3
117
Over run lamp
88
116
Main relay 5
(30A)* Injector #2
2 120
40
Injector #4
118
21
SCV
105
113
42
Accelerator 89
position 63
97
sensor 64
41
20 8 Tachometer
Barometric 61
pressure 71
sensor 60 18
37
Intake air 72
temperature
sensor 6
14
Boost 95
38 7 TOOL
pressure 91
sensor 109 52 1
Boost 74 5
temperature
sensor 43
62
1
CKP sensor 107
108 3
4
Memory clear switch
32
81
TSJJ0160
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
6
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
20
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
41
42
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
64
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

1 PG-POWER GND
3 PG-POWER GND
4 PG-POWER GND
6
8
9

12
13
14 OS-STARTR Starter cut relay
15 OS-OVHL Overheating lamp
16
18 CC-CAN-H CAN-HIGH
19
20 SG-SLD1 Accelerator position (AP) sensor shield
22
23
25
26
27
28
29 IS-IDLMNL Idle selector switch
30 IS-IDLUP Idle up switch
31 IS-IDLDWN Idle down switch
32 IS-MEMCL Memory clear switch
33 IS-REG Regulation mode switch
34
35
36
37 CC-CAN-L CAN-LOW
39
41 SG-5VRT1 Accelerator position (AP) sensor GND
42 SP-5V1 Accelerator position (AP) sensor power supply
43 PG-SIGN GND
44
45 IS-LOAD Load advance switch
46 IS-START Key switch start signal
47 ENGSTP Engine stop switch
48
49 IS-MDMAP0 Mode map switch 0

53
54
55
56
57
58
59
62 PG-SIGN GND
63 IA-ACCEL1 Accelerator position (AP) sensor 1 signal
65
66
68
69
70
73
75
76
77
78
sensor GND
81 PG-CASE GND

1 PG-POWER GND
3 PG-POWER GND
4 PG-POWER GND
6 OS-DIAGL Diagnosis lamp

8
9
12
13
14
15
16
18
19
20 SG-SLD1 Accelerator position (AP) sensor shield
22
23
25
26
27
28
29
30
31
32
33
34
35
36
37
39
41 SG-5VRT1 Accelerator position (AP) sensor GND
42 SP-5V1 Accelerator position (AP) sensor power supply
43 PG-SIGN GND
44
45
46
47
48

49
50
51
53
54
55
56
57
58
59
62 PG-SIGN GND
65
66
68
69
70
73
75
76
77
78
sensor GND
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 Camshaft position (CMP) sensor, common rail pressure sensor and EGR valve EGR
position sensor switch
88
89 IA-SCVLO SCVLO drive
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, crankshaft position (CKP) sensor power supply
96
98 IF-CAM Camshaft position (CMP) sensor signal
99
100 SG-SLD5 Camshaft position (CMP) sensor, common rail pressure sensor shield
101 SG-5VRT5 Camshaft position (CMP) sensor, common rail pressure sensor and EGR valve EGR
position sensor GND
102
103 OM-EBM2 EGR valve DC servomotor power supply input V
104
105 OS-SCVHI SCVHI drive
106
107 IF-CRANK Crankshaft position (CKP) sensor
108 SG-SLD4 Crankshaft position (CKP) sensor shield
109 SG-5VRT4 Boost pressure sensor, boost temperature sensor, crankshaft position (CKP) 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
114
115
116 OP-COM2 Injector power supply 2 (No. 2, No. 3 cylinders)
117 OS-INJ3 Injector 4

85
86
88 OS-OVRL Overrun lamp
96
99
position sensor GND
102
104
106
GND
112
114
115


85
86
88
96
99
position sensor GND
102
104
106
GND
112
114
115

Circuit diagram
(Refer to 1E-8, 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 machines manual.)

21 E-57
Main relay
40 E-57
E-57
B+
2
(30A)*
E-57
B+
5
(MAIN)*
Battery
TSWG0027
Key switch
A A
Battery OFF OFF
ON ON
START START
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
(100A)*
(15A)*
(10A)*
Starter for ECM control, glow circuit
(60A)* Starter relay
Main relay
Starter
Glow relay Starter cut relay
1 H-22
5
B/W
1 H-1
10 E-57 14 E-57 46 E-57
Glow Glow relay control

plug
Starter cut relay signal

TSJJ0021
Starter for safety relay, glow circuit

(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
CAN LOW CAN HIGH
Engine control
module (ECM)
KWP2000
81 E-57 4 E-57 3 E-57 1 E-57 43 E-57 62 E-57 52 E-57 38 E-57 37 E-57 18 E-57
CAN, GND, DLC circuits
1 FL-150 7 FL-150 14 FL-150 6 FL-150
CAN CAN
LOW HIGH
DLC
Machine control unit
5 FL-150 4 FL-150
CAN LOW CAN HIGH
TSJJ0022
(15A)* Main relay
A A
Machine trouble Boost Tachometer Meter

Diagnosis Engine oil QOS indicator Over run
diagnosis monitor temperature O/H lamp
lamp pressure lamp lamp lamp
lamp
Indicator lamp, tachometer circuit
6 H-6
Machine
control unit
CAN LOW CAN HIGH 1 E-164
O/H switch
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 102 E-56 8 E-57
Engine control
module (ECM)
Engine oil Boost Over run
Diagnosis pressure QOS indicator temperature lamp
lamp control lamp control lamp control lamp control control

Tachometer
CAN HIGH CAN LOW signal
TSJJ0023
Injector circuit
2 E-423 2 E-422 2 E-411 2 E-414
Injector Injector Injector Injector

(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)
1 E-423 1 E-422 1 E-411 1 E-414
2 2 2 2 2 2
R P G W L Y
3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56
Engine control
Cylinder No. 3 Cylinder No. 2 Cylinder No. 1 Cylinder No. 4 module (ECM)
Feedback Feedback Feedback Feedback

B+ B+
TSJJ0024
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)
SCVLO drive SCVHI drive
B+
TSHK0016
sensor signal 5V 5V sensor signal
5V
Engine coolant Vcc

Fuel temperature temperature sensor
sensor signal signal
19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56

pressure sensor circuit
3 H-6
7 H-20 11 H-20 10 H-20 9 H-20
0.75 0.75 0.75

B/Y L/Y W/B
0.75 0.75 0.75 0.75

Pulse
Y/G B/Y Y/G B/Y
matching
box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
* 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 LOW CAN HIGH
coolant
temperature
gauge
Machine trouble
diagnosis monitor
Vehicle speed sensor, fuel temperature sensor, engine coolant temperature sensor, engine oil
TSJJ0025
Engine control
module (ECM)
CKP sensor 5V Boost pressure
signal sensor signal
5V
Boost temperature
sensor signal
108 E-56 107 E-56 74 E-56 109 E-56 91 E-56 95 E-56
3 H-20 1 H-20 2 H-20 4 H-20 15 H-20 17 H-20 16 H-20 8 H-20
0.75 B
0.5 0.5 0.5

W/B Gr/B V/W 0.75 0.75 0.75 0.75 0.75
B/R R/L R/L L R/W
CKP sensor, boost temperature sensor, boost pressure sensor circuit
2 E-98 1 E-98 3 E-98 2 E-163 1 E-163 1 E-75 2 E-75 3 E-75


CKP sensor (MRE)
TSJJ0026
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+
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8

18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
CMP sensor, common rail pressure sensor, EGR circuit
O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
L G/Y W/L G/W W/B G/B W/R L/W
0.5 0.5 0.5

L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80
2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113

V
W U
CMP sensor (MRE) Common rail pressure sensor EGR valve
TSJJ0027
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 LOW CAN HIGH
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
TSJJ0028
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
CAN LOW CAN HIGH

E-57
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
13 12 11 10 9
8
1
7
2 6
5
4
TSJJ0124
Name
1. Engine coolant temperature sensor 8. EGR position sensor
2. SCV 9. Boost pressure sensor
3. Fuel temperature sensor 10. Boost temperature sensor
4. Engine oil pressure sensor 11. Glow plug
5. CKP sensor 12. Overheating switch
6. Common rail pressure sensor 13. CMP sensor
7. Injector
E411 E422 E423 E414
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4
1 2 1 2 1 2 1 2
2 2 2 2 2 2 2 2
L W G R P R Y W
E112
SENSOR:CAM ANGLE(G)
1 2 3 1
0 .5 0 .5 0. 5 5
T O/B Y B /W
GLOW PLUG(No.4)
H1
1 2
0 .75 0.7 5
B/Y Y/G E75
3
0 .75
R SENSOR:BOOST PRESS
SENSOR:WATER 1 2 3 4
1 2 3 0 .7 5 0 .7 5 0 .7 5 0 .7 5
0. 75 0. 75 0. 75 L G/Y G/W G/B
E90 1 R/L L R/W 5 6 7 8
0. 75 0 .7 5 0 .7 5 0 .7 5 0 .7 5
G L /W W /L W /B W /R
EGR VALVE
SWITCH:O/H
E163 E80
E164
SENSOR:MAT(BOOST TEMP)
1 2
0. 75 0. 75 1 2 3
E113 R/L B/R
0 .5 0 .5 0 .5
Gr/B W /B V /W
SENSOR:COMMON RAIL
SENSOR:NE.CRANK
1 2 3
0 .5 0. 5 0. 5 E98
L /W Br L
1 2
0. 75 0 .7 5
B/Y Y /G
SENSOR:FUEL TEMP
E93
1 2 3 4
0. 5 0. 5 0. 75 0. 5
W/ B Gr/B B V/W
5 6 7 8
0. 5 0. 75 0. 75 0. 75
T B/W Y/G R/W
9 10 11 12 1
1 2 0. 75 0. 75 0. 75 0. 5
W/ B L/ Y B/Y L 5
0.7 5 0 .75 B /W
R/W R/ B 13 14 15 16
0. 5 0. 5 0. 75 0. 75
SCV Br L/ W B/R L H22
17 18 19 20
0. 75 0. 5 0. 5
E161 R/L O/B Y
SENSOR:OIL PRESSRE 1 2 3
0. 75 0. 75 0. 75
B/ Y L/ Y W/ B H20
E76
3 2 1
0 .7 5 0 .7 5 0 .7 5
Y /G R /W R /B
4 3 2 1 6 5 4
2 2 0 .7 5 0 .7 5
W R G R
8 7 6 5
4 3 2 1
2 2 2 2 H6
L G P Y 0.75 0.75 0.75 0.75
L G/Y G/W G/B
12 11 10 9 8 7 6 5
0.75 0.75 0.75 0.75
L/W W/L W/B W/R
H12 H8
TSJJ0110
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 + E411
3 ECT meter Terminal
Number
E93 1 OSINJ1 signal/Injector #1
Terminal 2 Injector power supply 1
Number
1 Fuel temperature sensor GND E414
2 Fuel temperature sensor + Terminal
Number
E98 1 OSINJ3 signal/Injector #4
Terminal 2 Injector power supply 1

Number
1 CKP Vout E422
2 CKP GND Terminal
Number
3 CKP Vcc
1 OSINJ4 signal/Injector #2
2 Injector power supply 2
E423 Terminal
Terminal Number
Number 11
1 OSINJ2 signal/Injector #3 12
H20
H1 Terminal
Number
Terminal
Number 1 CKP GND
1 Glow 2 CKP Vout
3 CKP shield
H6
4 CKP Vcc
Terminal
Number 5 CMP Vout
1 SCV Lo 6 CMP / Common rail pressure sensor shield
2 SCV Hi 7 ECT +
3 Fuel temperature sensor + 8 Boost pressure sensor Vcc
4 ECT meter 9 Engine oil pressure sensor Vcc
5 10 Engine oil pressure sensor Vout
6 Overheating switch 11 Engine oil pressure sensor GND

12 Common rail pressure sensor Vcc
H8 13 Common rail pressure sensor Vout
Terminal 14 Common rail pressure sensor GND
Number
15 Boost temperature sensor +
1 EGR hall sensor U
16 Boost pressure sensor Vout
2 EGR hall sensor V
17 Boost pressure sensor GND
3 EGR hall sensor W
18 CMP GND
4 EGR Vcc
19 CMP Vcc
5 EGR motor U
20
6 EGR motor V
7 EGR motor W H22
8 EGR GND Terminal
Number
H12 1 Glow
Terminal
Number
1
2
9
10
Connector list No. Connector Face
No. Connector Face
1 2 3
E-98
E-56 003-505
Engine harness side (male terminal)

Machine harness side (female terminal) (Black)
(Black)
1 2 3
E-112
E-57 003-505

Machine harness side (female terminal) (Black)
(Black)
E-113
1 2 3
E-75
003-503
Engine harness side (male terminal) (Black)
(Light gray)
E-161
1 2 3
E-76
003-501 Engine harness side (male terminal)
Engine harness side (male terminal) (Light gray)
(Black)
1 2
E-163
E-80 002-500

(Black)
E-164
1 2
3
E-90 000-009
003-504
(Silver)
(Light gray)
E-411
E-93 Engine harness side (male terminal)

(Light gray)
(Green)
No. Connector Face No. Connector Face
H-6
E-414
Engine harness side (male terminal) Machine harness side (female terminal)
(Light gray)
H-8
E-422
(Light gray)
H-8
E-423
Machine harness side (female terminal)
(Light gray)
H-12
FB-124 Engine harness side (male terminal)

(Black)
(Black)
H-12
1 2 3 4 5 6 7 8
FL-150 9 10 11 12 13 14 15 16
Machine harness side (female terminal)
016-500
Engine harness side (male terminal) 1 2 3 4

5 6 7 8
9 10 11 12
H-20 13 14 15 16
17 18 19 20
1 2 3 020-500
FL-269
Engine harness-side (female terminal)
003-502 (Light gray)
4 3 2 1
8 7 6 5
12 11 10 9
H-20
16 15 14 13
H-1 20 19 18 17
020-501
000-009 Machine harness side (male terminal)

(Silver)
H-22
H-6
Engine harness-side (female terminal)
Engine harness side (male terminal) (Light gray)
(Black)
No. Connector Face
H-22
Machine harness side (male terminal)

List of Function Checks

List of function checks
Interview Check to comprehend the trouble symptom and diagnose properly based on a customers
complaint.
OBD system check Check to identify defective point of engine control system (inspection procedure)
Diagnosis lamp illumination cir- Check when diagnosis lamp does not come on when starter switch is turned ON.
cuit system check
Diagnosis lamp blinking circuit Check when diagnosis lamp does not blink (remains on) when diagnostic switch is turned
system check ON.
Scan tool power supply circuit Check when scan tool (Tech2) does not operate.
system check
Scan tool power supply circuit Check when scan tool (EMPSIII) does not operate.
system check
Scan tool communication circuit Check when scan tool (Tech2) cannot communicate with ECM.
system check
Starting circuit system check Check when starter does not operate.
Starting system check Check when starter operates but engine does not start.
Fuel system check Check when relevant points to fuel system may be faulty (inspection procedure).
Intake system check Check when relevant points to intake system may be faulty (inspection procedure).
Exhaust system check Check when relevant points to exhaust system may be faulty (inspection procedure).
EGR control system check Check when relevant points to EGR may be faulty (checking procedure).
QOS control system check Check when relevant points to QOS (glow) may be faulty (checking procedure).
CAN communication check Check when fault relevant to machine control unit and CAN communication between scan
tool and ECM may exist.
Machine-side check Check 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-297, 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.

2. Check the diagnosis lamp (trouble display Go to 1E-264,
monitor on the machine). Diagnosis lamp illu-
1
mination circuit sys-
Does the diagnosis lamp (trouble display monitor tem check, List of
on the machine) come on? Go to Step 2. Function Checks.
1. Connect the diagnosis connector.
If the machine is not equipped with diagno- Go to 1E-266,
2 sis lamp, Go to Step 3. Diagnosis lamp
2. Check the diagnosis lamp. blinking circuit sys-
tem check, List of
Does the diagnosis lamp blink? Go to Step 3. Function Checks.
3 Is the scan tool (KW communication) available? Go to Step 4. Go to Step 6.
1. Connect the scan tool. Go to 1E-269, Scan
2. Turn the key switch to ON. tool power supply
4 3. Turn the power switch of the scan tool to ON. circuit system check
(Tech2), List of
Does the scan tool powered ON? Go to Step 5. Function Checks.
Communicate with ECM using a scan tool. Go to 1E-273, Scan
tool communication
5 Does it communicate with ECM properly? circuit system
check, List of Func-
Go to Step 6. tion Checks.
Turn the key switch to START. Go to 1E-276,
Starting circuit sys-
6 Does the starter operate?
tem check, List of
Go to Step 7. Function Checks.
Turn the key switch to START. Go to 1E-281,
Starting system
7 Does the engine start?
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)* Main relay
A A
Diagnosis Engine oil QOS indicator Boost O/H lamp Over run Tachometer
lamp pressure lamp lamp temperature lamp
Machine trouble lamp Meter
diagnosis monitor
3 H-6
1 E-164
Machine
control unit
O/H
switch
CAN LOW CAN HIGH
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 102 E-56 8 E-57
Engine control
Engine oil Over run module (ECM)
Diagnosis pressure QOS indicator Boost temperature lamp
Tachometer signal
CAN HIGH CAN LOW
TSJJ0034
Description of circuit The 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, the followings Check the relevant items on the scan tool data
may 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.

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-90, Trouble Diagnostic Tools
(EMPS) for Industrial Engine in this section for
check and rewriting of ECM.
2. Rewrite the software if version upgraded is
necessary.
5 Note:
EGR valve position learning is required after
replacing or rewriting the ECM.
Refer to 1E-210, Installation of ECM, Engine con- Check the repair,
trol module (ECM), Engine Control System in this and Go to 1E-262,
section for learning of EGR. OBD system check,
List of Function
Is the procedure completed? Checks.
Replace the ECM.
Note:
6 Refer to 1E-210, Installation of ECM, Engine con- Check the repair,
trol module (ECM), Engine Control System in this and Go to 1E-262,
section for learning of EGR. OBD system check,
List of Function
Is the procedure completed? Checks.
Diagnosis lamp blinking circuit system check
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
81 E-57 4 E-57 3 E-57 1 E-57 43 E-57 62 E-57 52 E-57 38 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150 14 FL-150 6 FL-150
CAN CAN
LOW HIGH
DLC
5 FL-150 4 FL-150
CAN LOW CAN HIGH
TSJJ0033
Description of circuit The 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, the followings Check the relevant items on the scan tool data
may be the cause. display while moving the connector and the har-

2. Connect the DMM between the diagnosis con-
1 nector (male-side) and the ground. 0V
Is the DMM indication the specified value or more? Go to Step 2. Go to Step 3.

Check the installation condition of the ECM con-
nector.
2 1. Check for play or looseness in the connection.

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

1. Check for the followings in the circuit between
ECM and diagnosis connector using breaker
box or DMM.
cedure, Diagnosis lamp blinking circuit system
3 check, List of Function Checks.
Open circuit
High resistance

diagnosis 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.
7 Note:
Refer to 1E-210, Installation of ECM, Engine con-
trol module (ECM), Engine Control System in this
section for learning of EGR.
Is the procedure completed? Verify repair. Go to Step 8.


Replace the ECM.
Note:
8 Refer to 1E-210, Installation of ECM, Engine con-
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.
Ways to measure voltage and resistance are different
when using a breaker box.
Refer to 1E-194, Example of use for breaker box,
Breaker box inspection procedure, How to Use Breaker
Box.
Name
1. Breaker box
2. DMM
Step Item to be Checking Measuring condition Measuring terminal Normal Abnormal

checked method No. value value
3 Open circuit/ Resistance Key switch OFF 52 Diagnosis con- 100 or less 10 M or
high resistance measurement nector terminal more
Short circuit to Resistance Key switch OFF 52 GND 10 M or 100 or less
ground measurement more
Scan tool power supply circuit system check (Tech2)
TSWG0162
Name
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
Diagnostic aid Check the relevant items on the scan tool data
If the intermittent trouble is suspected, the followings display while moving the connector and the har-
may 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.
Test description
Important:
Before starting this diagnostic step, check if the
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 the specified value or more? Go to Step 2. the battery.
Check for poor contact in the scan tool-side cable.
2
Is the fault 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 fault detected? the scan tool. Go to Step 5.

1. Connect the scan tool to the machine. Check the repair,
2. Turn the power switch of the scan tool to ON. and Go to 1E-262,
5 OBD system check,
Does the scan tool powered ON? List of Function
Checks. Go to Step 1.
Scan tool power supply circuit system check (EMPSIII)
1 2
TSJJ0129
Name
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:
Power supply voltage for the scan tool is the same Poor contact between terminal and wire
as one for the machines battery. Damaged harness
Test description
Important:
Before starting this diagnostic step, check if the
scan tool operates properly on other machine.
causes.

Check the voltage of battery on the machine using
1 DMM. 18V Charge or replace
Is the voltage the specified value or more? Go to Step 2. the battery.
Check for poor contact in the scan tool-side cable.
2
Correct the connection of the scan tool.
3
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 fault detected? the scan tool. Go to Step 5.

1. Connect the scan tool to the machine. Check the repair,
2. Turn the power switch of the scan tool to ON. and Go to 1E-262,
5 OBD system check,
Does the scan tool powered ON? List of Function
Scan tool communication circuit system check
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
81 E-57 4 E-57 3 E-57 1 E-57 43 E-57 62 E-57 52 E-57 38 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150 14 FL-150 6 FL-150
CAN CAN
LOW HIGH
DLC
5 FL-150 4 FL-150
CAN LOW CAN HIGH
TSJJ0033
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

Perform the OBD system check. Go to 1E-262, OBD
system check, List
1 Is the procedure completed?
of Function
Go to Step 2. Checks.
nector.


1. Check the DLC for the following conditions.
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.
4 Open circuit
High resistance
Short circuit to ground

1. Connect the scan tool.
5
3. Communicate with ECM using a scan tool.
Go to Diagnostic
Does it communicate with ECM properly? aid. Go to Step 6.
necessary.
7 Note:

Replace the ECM.
Note:


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

Box.
Name
1. Breaker box
2. DMM

4 Open circuit/ Resistance Key switch OFF 38 DLC terminal No. 100 or less 10 M or
high resistance measurement 7 more
Starting circuit system check
Starter ECM control
Key switch
A A
OFF OFF
ON ON
START START
Battery B Br C B ACC Br C
(ON) (ST) (ON) (ST)
(100A)*
(15A)*
(10A)*
Main relay
Starter
1 H-22
5
B/W
1 H-1
10 E-57 14 E-57 46 E-57
Engine control
module (ECM)
plug
TSJJ0032
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
The 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
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 the Starter switch (ST) on the data
4 display using a scan tool.
Does the Starter switch (ST) display ON? Go to Step 6. Go to Step 5.

key switch and ECM using breaker box or
DMM.
cedure, Starting circuit system check, List of
5 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
Turn the key switch to START.
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.
14 Note:

Replace the ECM.
Note:

Turn the key switch to START. Check the repair,
and Go to 1E-262,
16 Does the starter operate? OBD system check,
List of Function
key switch and ECM using breaker box or
DMM.
cedure, Starting circuit system check, List of
17 Function Checks.
Open circuit
High resistance


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

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.

Box.
Name
1. Breaker box
2. DMM

5, 17 Open circuit/ Resistance Key switch OFF 46 Key switch 100 or less 10 M or
high resistance measurement START terminal more
6, 18 Open circuit/ Resistance Key switch OFF Starter cut relay 100 or less 10 M or
high resistance measurement Relay alone Switch-side terminal more
8, 20 Open circuit/ Resistance Key switch OFF Starter relay 100 or less 10 M or
high resistance measurement Relay alone Switch-side terminal more
Relay ON
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 CMP sensor, the engine will
the cause of that engine does not start. Followings are not start until memory clear is performed.
the preconditions for performing this diagnosis. The engine does not start with the emergency stop
Battery is fully charged, and battery cable is switch is activated. Check the machines manual to
securely connected. check if the emergency stop switch is equipped.
If the intermittent trouble is suspected, the followings
Engine speed at cranking is normal.
may be the cause.
Sufficient amount of fuel is supplied.
No air mixed in the fuel.
Air cleaner element and fuel filter is normal.
Correct fuel is used.
Important: The following inspections are necessary to detect these
Start with the DTC diagnosis relevant to fuel sys- causes.
tem if there is any. Improper connection of harness connector and
ECM connector
Unmatched terminals are fitted.
Damage of connector lock 5. If the SCVLO drive circuit is shorted to ground, the
Poor contact between terminal and wire SCV drive current will not be more than 900mA.
6. If the engine starts with the SCV connector discon-
Test description nected, SCV system may be faulty. Also, if the engine
does not start, the fuel system may be faulty.
Numbers below indicate step numbers in the chart. 7. Check the signal and operation of each sensor and
injector.

1 OFF, then Go to
Check if the overheating switch is installed, and
check the switch for faults.
Did the ECM stop the engine in an emergency
2 due to faults in the harness or switches?
If the trouble is detected, repair or replace.

2. Crank the engine for 15 seconds.
3 3. Check the DTC. Go to the relevant
diagnosis of DTC
Is DTC detected? detected. Go to Step 4.
While cranking the engine, check for SCV F/B on
5 the data display using a scan tool. 900mA
Is the SCV F/B the specified value or more? Go to Step 6. Go to Step 7.
1. Disconnect the SCV connector. Go to 1E-284, Fuel
2. Crank the engine. system check, List
6
of Function
Does the engine start? Go to DTC P0090. Checks.
Repair the SCVLO drive circuit between the ECM
7 and the SCV.
1. Check the relevant items to the following using
a scan tool to see if the values are normal.
Engine coolant temperature (ECT) sensor
8 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 CKP sen-
sor rotor
9 Excessive clogging in intake system
Excessive clogging in exhaust system
Is the fault detected? Go to Step 10.


1. Clear the DTC.
Refer to 1E-21, How to clear DTC, Procedure
of Trouble Diagnosis in this section for how to
clear DTCs.
10 2. Turn the key switch to OFF for more than 10
seconds.
3. Start the engine.

Check the DTC. Check the repair,
and Go to 1E-262,
11 Is DTC detected? Go to the relevant OBD system check,
diagnosis of DTC List of Function
detected. Checks.
1. Check the SCVLO drive circuit between the
ECM and the SCV.
12 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 CKP sen-
sor rotor
13 Excessive clogging in intake system
Excessive clogging in exhaust system
Is the fault detected? Go to Step 10.

Fuel system check
3
1
4
5
TSJJ0103
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- The 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
may be the cause.

Check the fuel quality.
1. Drain fuel from the fuel tank.
2. Add proper fuel.
1
3. Let the air bleed from the fuel.
Does the engine start? Go to Step 7. 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.
Disconnect the fuel line from the upstream side of
the supply pump, and check the fuel discharge.
Note:
3 Refer to 1E-286, Fuel discharge inspection proce-
dure, Fuel system check, List of Function Checks
for work procedure.
Is the fuel discharge normal? Go to Step 9. Go to Step 4.

Check if there are additional filters or parts, other
than genuine fuel filter, pre-filter and electromag-
4 netic pump, in the machines fuel pipe.
Are there any additional filters or parts? Go to Step 5. Go to Step 6.

1. Remove the additional filter and bleed air.
If the fuel resistance is increased, the DTC
5 such as P1093 may be detected.
Does the engine start? Go to Step 7. Go to Step 6.

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.
6 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.
7 2. If the fault is detected, repair as required.

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
8 Wrong assembly of fuel pipe
Clogging at filler neck
Water mixed in fuel


Let the air bleed from the fuel.
Note:
Refer to 1E-201, Bleed air from fuel system,
9 Description of function and operation for engine
control (common rail) system, Engine Control Sys-
tem for work procedure.
Fuel discharge inspection procedure 4. Check for air mixed in fuel

Check the fuel discharge on the fuel system upstream Connect a clear pipe to fuel line, and check that no
side in the following procedure. air is mixed in discharged fuel.
If air is mixed in fuel, determine and repair the
1. Disconnect the fuel line from the inlet of the supply
point, where the air enters, on the upstream
pump.
side of the low pressure line.
2. Activate the electromagnetic pump.
If no air is mixed in fuel, fault inside the supply
3. Check if fuel is discharged from the fuel line. pump may be suspected. Replace the SCV. If
If fuel is discharged, go to 4. Check for air this does not correct the fault, replace the sup-
mixed in fuel. ply pump.
If no fuel is discharged, go to 5. Check the
electromagnetic pump. Note:
Refer to 1E-213, SCV Replacement procedure,
Engine component location diagram, Engine Con-
6 trol System in this section for the SCV replacement
procedure.
5
4 Refer to Engine section in the service manual for
replacing the supply pump.
3
6
5
4
TSHK0164
Name
1. Supply pump
2. Fuel tank
3. Pre-fuel filter 1
4. Electromagnetic pump 2
5. Fuel filter
6. Supply pump inlet TSHK0165
Name
1. Supply pump
2. Fuel tank
3. Pre-fuel filter
4. Electromagnetic pump
5. Fuel filter
6. Clear pipe
5. Check the electromagnetic pump
Disconnect the pipe from the outlet side of the
electromagnetic pump, and activate the pump.
If fuel is discharged from the electromagnetic
pump, check the lines of other than this pump
for faults.
If no fuel is discharged from the electromag-
1
netic pump, check the pump according to Elec-
2
tromagnetic pump inspection procedure.
5 3
4
6 TSHK0106
Name
2. + terminal
3. - terminal
1
3. Blow air into the inlet of the electromagnetic pump
2
with your mouth.
The internal seal may be stuck. Blow air to elim-
TSHK0167 inate sticking.
Name
1. Supply pump
2. Fuel tank
3. Pre-fuel filter 2
5. Fuel filter
6. Electromagnetic pump outlet
Electromagnetic pump inspection procedure

1. Turn the key switch to ON, and check for pulsation
in the fuel hose. 1
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-
TSHK0107
cuit, short circuit or poor contact in the
machine-side harness. Repair the faulty part, Name
and check again from Step 1. 1. Fuel inlet port
2. Fuel outlet port
If the electromagnetic pump does not operate,
replace the pump.
4. Install the removed parts, and check again from
Step 1.
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 machines 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
3 part.
Check for bend or improper piping that may
cause increasing in intake air resistance.

Repair or replace the intake pipe.
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:
6 For work procedure, refer to Engine section in the
service manual.

Repair the machine.
7
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)
EGR EGR EGR

position position position
CMP sensor Common rail pressure sensor sensor sensor
signal sensor signal signal signal signal
5V
B+ B+ B+
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8

18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
0.5 0.5 0.5

L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80
2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113

V
W U
TSJJ0038
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 70C (158F).
3 3. Check the value for EGR position using a 3%
scan tool.
Is EGR position within the specified value? Normal system Go to Step 4.

1. Perform EGR control test using a 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 70C (158F).
7 3%
3. Check the value for EGR position using a
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 fault 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
TSJJ0138
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
Key switch
A A
OFF OFF
ON ON
START START
(ON) (ST) (ON) (ST)
(100A)*
(15A)*
(10A)*
Main relay
Starter
1 H-22
5
B/W
1 H-1
10 E-57 14 E-57 46 E-57
Engine control
module (ECM)
plug
TSJJ0032
(15A)* Main relay
A A
diagnosis monitor
3 H-6
1 E-164
Machine
control unit
O/H
switch
CAN LOW CAN HIGH
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 102 E-56 8 E-57
Engine control
Tachometer signal
CAN HIGH CAN LOW
TSJJ0034
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. Go to 1E-262, OBD
system check, List
of Function

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 M 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.
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 M 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 2. Rewrite the software if version upgraded is

necessary. If rewriting is not necessary, go to
the procedure 3.
3. Replace the ECM.

1. Perform Glow plug relay test using a 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.
6(Normal
15 3. Measure the resistance between each glow
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 16V
glow plug harness terminal and the ground
using DMM.
Are the voltages at all the cylinders the specified

value or more? 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 the specified

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
On some machines, the diagnosis lamp comes on instead of trouble display monitor on the machine.
Fault Recov
Diag-
Flash DTC descrip- Item to be Preconditions when judg- Behavior when trou- ery
DTC DTC set condition nosis
code tion detected DTC is set ment ble occurs from
lamp
period failure
P0087 227 No pump pres- Common rail 900 rpm or more Actual rail pres- 3 sec- Intense engine vibra- ON *1
sure feed (fuel pressure does sure is 15 Mpa onds tion, rough idling,
leakage) not increase to (2,176 psi) or output lowering, blow
the required less. up fault, black smoke
area. emitted, and exces-
sive output are possi-
ble.
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 5 sec- Intense engine vibra- ON *1
pressure fault pressure voltage is 18V or more than 185 onds tion, rough idling,
(1st stage) abnormal more. MPa (26832 psi). output lowering, blow
increase DTC P0088, P0192, up fault, black smoke
P0193 or P1635 is emitted, and exces-
not detected. sive output are possi-
Actual rail pressure ble.
is 2 Mpa (290 psi) or Back-up:
more, and 70 rpm or Limited injection
more. amount 3 (multi-
injection stopped)
Target RP upper
psi})
P0088 118 Common rail Common rail Key switch input Common rail 5 sec- Intense engine vibra- ON *1
pressure fault pressure voltage is 18V or pressure fault (1st onds tion, rough idling,
(2nd stage) abnormal more. stage) is com- output lowering, blow
increase DTC P0088, P0192, pleted, and rail up fault, black smoke
P0193 or P1635 is pressure is more emitted, and exces-
not detected. than 190 MPa sive output are possi-
Actual rail pressure (27557 psi). ble.
is 2 Mpa (290 psi) or Back-up:
more, and 70 rpm or Limited injection
more. amount 3 (multi-
injection stopped)
Target RP upper
psi})
P0089 151 Common rail Common rail Key switch input Actual rail pres- 5 sec- Intense engine vibra- ON *1
pressure fault pressure voltage is 18V or sure is 40 MPa onds tion, rough idling,
(Excessive abnormal more. (5802 psi) or output lowering, blow
pressure feed increase DTC P0089, P0192, more higher than up fault, black smoke
in pump) P0193 or P1635 is target rail pres- emitted, and exces-
not detected. sure. sive output are possi-
Coolant tempera- ble.
ture is 60C (140F) Back-up:
or more, and 375 rpm Limited injection
or more. amount 3 (multi-
Duty to SCV is 40% injection stopped)
or more, or SCV tar- Target RP upper
get pressure feed is limit (80 MPa {11603
90 mm3/sec psi})
(0.0055cuin/sec) or
less.
Fault Recov
Diag-
lamp
period failure
P0090 247 SCV drive sys- Open/short cir- Main relay power When SCV drive Approx. Engine stall and/or ON *2
tem open circuit of SCV/ supply voltage is 18V current exceeds 1.5 sec. engine blow up are
cuit, +B short harness or more. 2400 mA or drops possible depending
or ground short DTC P1630 is not below 50 mA, or on the condition of
detected. when the differ- open/short circuit.
SCV drive duty is ence between tar- Black smoke emitted,
between 10 and get and actual excessive output
90%. current exceeds Back-up:
1000 mA or more. Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
psi})
P0107 71 Barometric Open/short cir- Key switch input Barometric pres- Approx. Due to back-up ON *2
pressure sen- cuit/deteriora- voltage is 18V or sure sensor volt- 5 sec. equivalent to 2000 m
sor fault (low tion of sensor more. age is lower than (6562 ft)
voltage fault) or harness DTC P1630 or 0.5 V. Black smoke emit-
P1632 is not ted at high altitude
detected. Back-up:
Barometric pres-
sure default setting
(80 kPa {11.6 psi})
EGR stopped
P0108 71 Barometric Short circuit in Key switch input Barometric pres- Approx. Due to back-up ON *2
pressure sen- sensor or har- voltage is 18V or sure sensor volt- 5 sec. equivalent to 2000 m
sor fault (high ness more. age is more than (6562 ft)
voltage fault) DTC P1630 or 3.8 V. Black smoke emit-
P1632 is not ted at high altitude
detected. Back-up:
Barometric pres-
sure default setting
(80 kPa {11.6 psi})
EGR stopped
P0112 22 Intake air tem- Short circuit in Key switch input Intake air temper- Approx. Not in particular ON *2
perature sen- sensor or har- voltage is 18V or ature sensor volt- 3.5 sec. Back-up:
sor fault (low ness more. age is less than Intake air tempera-
voltage fault) DTC P1630 or 0.1 V. ture default setting
P1632 is not (at starting: 10C
detected. {14F}, at running:
25C {77F})
EGR stopped
P0113 22 Intake air tem- Open/short cir- Key switch input Intake air temper- Approx. Not in particular ON *2
perature sen- cuit/deteriora- voltage is 18V or ature sensor volt- 3.5 sec. Back-up:
sor fault (high tion of sensor more. age is more than Intake air tempera-
voltage fault) or harness DTC P1630 or 4.95 V. ture default setting
3 minutes or more 25C {77F})
has elapsed after EGR stopped
starting engine.
P0117 23 Engine coolant Short circuit in Key switch input Engine coolant Approx. At normal tempera- ON *2
temperature sensor or har- voltage is 18V or temperature sen- 3.5 sec. ture: Black smoke
sensor fault ness more. sor voltage is less emission, greater
(low voltage DTC P1630 or than 0.1 V. engine combustion
fault) P1633 is not noise possible.
detected. During idling at low
atmospheric temper-
atures: Rough idling,
engine stall, white
smoke emission pos-
sible.
Back-up:
Coolant tempera-
ture default setting
(at starting: 20C
{4F}, at running:
80C {176F})
EGR stopped
Fault Recov
Diag-
lamp
period failure
P0118 23 Engine coolant Open/short cir- Key switch input Engine coolant Approx. At normal tempera- ON *2
temperature cuit/breakage voltage is 18V or temperature sen- 3.5 sec. ture: Black smoke
sensor fault of sensor or more. sor voltage is emission, greater
(high voltage harness DTC P1630 or more than 4.85 V. engine combustion
fault) P1633 is not noise possible.
detected. During idling at low
3 minutes or more atmospheric temper-
has elapsed after atures: Rough idling,
starting engine. engine stall, white
smoke emission pos-
sible.
Back-up:
Coolant tempera-
ture default setting
(at starting: 20C
{4F}, at running:
80C {176F})
EGR stopped
P0182 211 Fuel tempera- Short circuit in Key switch input Combustion tem- Approx. Not in particular ON *2
ture sensor sensor or har- voltage is 18V or perature sensor 3.5 sec. Back-up:
fault (low volt- ness more. voltage is less Fuel temperature
age fault) DTC P1630 or than 0.1 V. default setting
70C {158F})
P0183 211 Fuel tempera- Open/short cir- Key switch input Combustion tem- Approx. Not in particular ON *2
ture sensor cuit/breakage voltage is 18V or perature sensor 3.5 sec. Back-up:
fault (high volt- of sensor or more. voltage is more Fuel temperature
age fault) harness DTC P1630 or than 4.85 V. default setting
3 minutes or more 70C {158F})
has elapsed after
starting engine.
P0192 245 Common rail Short circuit in Key switch input Common rail Nearly Engine stall possible ON *2
pressure sen- sensor or har- voltage is 18V or pressure sensor simulta- Output lowering
sor fault (low ness 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
Actual rail pres-
sure default value
(80Mpa {11603 psi})
P0193 245 Common rail Open/short cir- Key switch input Common rail Nearly Engine stall possible ON *2
pressure sen- cuit/breakage voltage is 18V or pressure sensor simulta- Output lowering
sor fault (high of sensor or more. voltage is more neous to Back-up:
voltage fault) harness DTC P1630 or than 4.5 V. fault Rail pressure feed-
P1635 is not occur- back control
detected. rence stopped
Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Actual rail pres-
sure default value
(80Mpa {11603 psi})
P0201 271 Open circuit in Open/short cir- Main relay power No injector 1 Approx. Intensive engine ON *1
injection noz- cuit in electrical supply voltage is 18V monitor input sig- 2.5 sec. vibration, rough
zle #1 drive wiring No. 1 or more. nal exists. idling, output lower-
system cylinder injec- 70 rpm or more ing, blow up fault
tor DTC P0611, P1261 Back-up:
or P0201 is not Injection for cylin-
detected. der #1 stopped,
EGR stopped
Fault Recov
Diag-
lamp
period failure
EGR stopped
EGR stopped
EGR stopped
P0219 543 Overrun Engine speed Key switch input When engine Approx. Assuming a shovel ON *2
abnormally voltage is 18V or speed exceeds 0.5 sec. will not blow more
high more. the specified than the specified
speed. speed.
15t: 2400 rpm Back-up:
12t: 2200 rpm Limited injection
amount 1
Limitation is lifted if
the speed
decreases
P0219 543 Overrun Engine speed Key switch input When engine Approx. Assuming a shovel ON *2
abnormally voltage is 18V or speed is more 0.5 sec. will not blow more
high more. than 2500 rpm. than 2500rpm.
Back-up:
Limited injection
amount 1
the speed
decreases
P0219 543 Overrun Engine speed Key switch input When engine Approx. Assuming a vibrating ON *2
abnormally voltage is 18V or speed exceeds 0.5 sec. roller will not blow
high more. the specified more than 2675 rpm.
speed. Back-up:
33t: 2300 rpm Limited injection
29t: 2000 rpm amount 1
the speed
decreases
P0237 32 Boost pres- Open/short cir- Key switch input Boost pressure Approx. Black smoke emitted ON *2
sure sensor cuit/breakage voltage is 18V or sensor voltage is 2.5 sec. Back-up:
fault (low volt- of sensor or more. less than 0.1V. Boost pressure
age fault) harness DTC P1630 or default setting (160
P1634 is not kPa)
detected. Boost pressure cor-
rection/EGR
stopped
Fault Recov
Diag-
lamp
period failure
P1634 is not kPa)
rection/EGR
stopped
P1634 is not kPa)
rection/EGR
stopped
P0238 32 Boost pres- Short circuit in Key switch input Boost pressure Approx. Black smoke emitted ON *2
sure sensor sensor or har- voltage is 18V or sensor voltage is 2.5 sec. Back-up:
fault (high volt- ness more. more than 4.9V. Boost pressure
age fault) DTC P1630 or default setting (160
P1634 is not kPa)
rection/EGR
stopped
P1634 is not kPa)
rection/EGR
stopped
P1634 is not kPa)
rection/EGR
stopped
P0335 15 Crank sensor Open circuit in CMP sensor pulse Cam signal exists When Output lowering, ON *1
fault (no signal) sensor/wiring is normal. but no crank sig- trouble white smoke emis-
DTC P0335, P0336, nal. occurs sion, intense engine
P0340, P0341 or 14 out of vibration possible
P1345 is not 21 sam- Engine stall possi-
detected. ples. ble (restart is possi-
Engine is running. ble when cam sensor
is normal.)
Back-up:
Control based on
cam when cam sen-
sor is normal
Fault Recov
Diag-
lamp
period failure
P0336 15 Crank sensor Broken teeth/ CMP sensor pulse Number of pulse When Output lowering, ON *1
fault (signal unnecessary is normal. for crank signal is trouble white smoke emis-
fault) signal mixed DTC P0335, P0336, mismatched. occurs sion, intense engine
(such as short P0340, P0341 or 14 out of vibration possible
circuit with P1345 is not 21 sam- Engine stall possi-
other wiring) detected. ples. ble (restart is possi-
Engine is running. ble when cam sensor
is normal.)
Back-up:
Control based on
cam when cam sen-
sor is normal
P0340 14 Cam sensor Open circuit in Key switch input Crank signal When Behavior does not ON *1
fault (no signal) sensor/wiring voltage is 18V or exists but no cam trouble change during
more. signal. occurs 7 engine running.
Crank pulse is nor- out of 8 After engine stalls,
mal. sam- engine will not start.
DTC P0335, P0336, ples. Back-up:
P0340, P0341, Engine running
P1345, or P1635 is based on crank
not detected. when it is normal
Engine is running. After engine stops:
Unable to identify
cylinder (unable to
restart)
P0341 14 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 short Crank pulse is nor- out of 8 After engine stalls,
circuit with mal. sam- engine will not start.
other wiring) DTC P0335, P0336, ples. Back-up:
P0340, P0341, Engine running
P1345, or P1635 is based on crank
not detected. when it is normal
Engine is running. After engine stops:
Unable to identify
cylinder (unable to
restart)
P0380 66 Glow relay fault Lamp fault Key switch input No glow relay When Operation is not ON *1
voltage is between monitor signal trouble affected.
16 V 32 V. exists at the glow occurs Back-up:
relay drive 25 out of No back-up action
instruction. 30 sam-
ples.
P0380 66 Glow relay fault Lamp fault Key switch input No glow relay When Operation is not ON *1
voltage is between monitor signal trouble affected.
16 V 32 V. exists at the glow occurs Back-up:
relay drive 25 out of No back-up action
instruction. 30 sam-
ples.
P0487 44 EGR position Open/short cir- Main relay input EGR position out- Approx. Exhaust gas is ON *2
fault (Brushless cuit/breakage voltage is 18 V or put signal is 2.5 sec. affected.
specification) of sensor or more. abnormal. Back-up:
harness DTC P1630 or Instruction to fully
P1635 is not close EGR valve
detected.
P0488 45 EGR valve Trouble/open DTC P1630, P1635 Difference Approx. Exhaust gas is ON *1
control fault circuit or valve or P0488 is not between target 9.5 sec. affected.
engage/stuck detected. valve lift and Back-up:
in drive motor Main relay voltage actual position is Instruction to fully
side is between 20 32 more than 20%. close EGR valve
V.
Difference between
target EGR opening
angle and actual one
is 20% or less.
Fault Recov
Diag-
lamp
period failure
P0522 294 Engine oil Open/short cir- Key switch input Engine oil pres- Approx. Operation is not ON *2
pressure sen- cuit/breakage voltage is 18V or sure sensor volt- 3.5 sec. affected.
sor fault (low of sensor or more. age is less than Back-up:
voltage fault) harness DTC P1633 is not 0.098V. Engine oil pressure
detected. default setting (120
kPa)
P0523 294 Engine oil Short circuit in Key switch input Engine oil pres- Approx. Operation is not ON *2
pressure sen- sensor or har- voltage is 18V or sure sensor volt- 3.5 sec. affected.
sor fault (high ness more. age is more than Back-up:
voltage fault) DTC P1633 is not 4.85V. Engine oil pressure
detected. default setting (120
kPa)
P0601 53 ROM fault ROM fault ROM is faulty. Engine stopped ON *2
Reflash failure Back-up:
Engine stopped
P0603 54 EEPROM fault EEPROM fault EEPROM is Operation is not ON *2
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
100 msec after neous to Limited injection for
key switch ON. fault amount 1 100ms
(SUB-CPU resets occur- ec
CPU.) rence only
after
KEY-
ON.

Sub-CPU detects Nearly Unable to start ON Diag-
main CPU fault in simulta- Back-up: nosed
100 msec after neous to SUB-CPU stops for
key switch ON. fault CPU. 100ms
(SUB-CPU resets occur- ec
CPU.) rence only
after
KEY-
ON.
P0606 52 CPU monitor- Sub-CPU fault 480 msec or more RUN-SUB pulse Nearly Output lowering ON *2
ing IC fault has elapsed after key does not change simulta- Back-up:
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 16 rence
V.
P0611 34 Charge circuit ECU charge Main relay power When charge cir- Approx. Intensive engine ON *2
fault (bank 1) circuit 1 fault supply voltage is 18V cuit bank 1 volt- 1.5 sec. vibration, rough
(internal burn- or more. age inside ECU is idling, output lower-
out, open cir- low. ing, blow up fault,
cuit, etc.) engine stall are pos-
sible.
Back-up:
Common 1 stop (#1,
#4 cylinders
stopped), EGR
stopped
P0612 34 Charge circuit ECU charge Main relay power When charge cir- Approx. Intensive engine ON *2
fault (bank 2) circuit 2 fault supply voltage is 18V cuit bank 2 volt- 1.5 sec. vibration, rough
(internal burn- or more. age inside ECU is idling, output lower-
out, open cir- low. ing, blow up fault,
cuit, etc.) engine stall are pos-
sible.
Back-up:
Common 2 stop (#2,
#3 cylinders
stopped), EGR
stopped
Fault Recov
Diag-
lamp
period failure
P0650 77 Check engine Lamp fault Key switch input No signal on the Approx. Operation is not Does *1
lamp fault voltage is 16V or check engine 1.5 sec. affected. not
more. lamp monitor Back-up: come
DTC P0650 is not when the check No back-up action on.
detected. engine lamp was
instructed to
come on, or sig-
nal remains on
the check engine
lamp monitor
when check
engine lamp was
instructed to be
turned off.
P1093 227 No pump pres- Fuel leakage Key switch input Actual rail pres- 5 sec- Intense engine vibra- ON *1
sure feed (fuel (large amount) voltage is 18V or sure is lower than onds tion, rough idling,
leakage) more. target rail pres- output lowering, blow
1200 rpm or more sure by 50 MPa up fault, black smoke
Duty to SCV is 33% (7252 psi) or less. emitted, and exces-
or less, or pressure sive output are possi-
feed is 28000mm3/ ble.
sec (1.7cuin/sec) or Back-up:
more. Limited injection
DTC P0090, P0192, amount 3 (multi-
P0193, P0201, injection stopped)
P0202, P0203, Target RP upper
P0204, P0611, limit (80 MPa {11603
P0612, P1093, psi})
P1095, P1261,
P1262 or P1635 is
not detected.
P1095 225 Pressure lim- Pressure lim- Key switch input Pressure limiter is 1 sec- Output lowering ON *1
iter open iter is opened. voltage is 18V or opened. onds Back-up:
more. Limited injection
DTC P1095, P0192, amount 1
P0193, P1630 or
P1635 is not
detected.
50 rpm or more
P1112 295 Boost tempera- Open/short cir- Key switch input Boost tempera- Approx. Operation is not ON *2
ture sensor cuit/breakage voltage is 18V or ture sensor volt- 3.5 sec. affected.
fault (low volt- of sensor or more. age is less than Back-up:
age fault) harness DTC P1634 is not 0.1 V. Boost temperature
detected. default setting
(30C {86F})
P1113 295 Boost tempera- Short circuit in Key switch input Boost tempera- Approx. Operation is not ON *2
ture sensor sensor or har- voltage is 18V or ture sensor volt- 3.5 sec. affected.
fault (high volt- ness more. age is more than Back-up:
age fault) DTC P1634 is not 4.95V. Boost temperature
detected. default setting
Coolant tempera- (30C {86F})
ture is 50C (122F)
or more, or 5 minutes
or more has elapsed
after starting engine.
P1173 542 Overheat Overheat con- Key switch input Coolant tempera- Approx. Operation is not Does *2
dition voltage is 18V or ture is more than 5 sec. affected. not
more. 110C (230F). Back-up: come
DTC P1630, P1633, No back-up action on.
P0117 or P0118 is
not detected.
During operation
Fault Recov
Diag-
lamp
period failure
P1261 158 Injection nozzle Open/short cir- Main relay power No injector 1 and Approx. Intensive engine ON *1
common 1 cuit in injector supply voltage is 18V 4 monitor input 2.5 sec. vibration, rough
drive system common 1-side or more. signal exists. idling, output lower-
fault electrical wir- 70 rpm or more ing, blow up fault
ing, EDU out- None of the follow- Engine stall is possi-
put part fault ing DTC sets are ble.
detected; DTC Back-up:
P0611, P1261 and Common 1 stop (#1,
P0201, P0204. #4 cylinders
stopped), EGR
stopped
P1262 159 Injection nozzle Open/short cir- Main relay power No injector 2 and Approx. Intensive engine ON *1
common 2 cuit in injector supply voltage is 18V 3 monitor input 2.5 sec. vibration, rough
drive system common 2-side or more. signal exists. idling, output lower-
fault electrical wir- 70 rpm or more ing, blow up fault
ing, EDU out- None of the follow- Engine stall is possi-
put part fault ing DTC sets are ble.
detected; DTC Back-up:
P0612, P1262 and Common 2 stop (#2,
P0202, P0203. #3 cylinders
stopped), EGR
stopped
P1271 24 Accelerator Difference in Key switch input Difference in Approx. 1 system fault: No Does *1
sensor 1-2 opening angle voltage is 18V or opening angle 2.5 sec. back-up not
comparison between accel- more. between acceler- 2 system fault: Accel- come
fault erator sensors DTC P1630, P1631, ator sensors 1 erator opening angle on.
1-2 is 45% or P1271, P1277, and 2 is 45% or is controlled to 0%.
more. P1278, P1282 or more. Back-up:
P1283 is not 1 system fault: No
detected. back-up
2 system fault:
Accelerator open-
ing angle is con-
trolled to 0%.
P1277 24 Accelerator Open/short cir- Key switch input Accelerator sen- Approx. 1 system fault: No Does *1
sensor 1 fault cuit/breakage voltage is 18V or sor 1 voltage is 0.5 sec. back-up not
(low voltage of sensor or more. lower than 0.2 V. 2 system fault: Accel- come
fault) harness DTC P1630, P1277 erator opening angle on.
or P1631 is not is controlled to 0%.
detected. Back-up:
1 system fault: No
back-up
2 system fault:
Accelerator open-
ing angle is con-
trolled to 0%.
(high voltage of sensor or more. more than 4.9 V. 2 system fault: Accel- come
detected. Back-up:
1 system fault: No
back-up
2 system fault:
Accelerator open-
ing angle is con-
trolled to 0%.
Fault Recov
Diag-
lamp
period failure
(low voltage of sensor or more. lower than 0.2 V. 2 system fault: Accel- come
detected. Back-up:
1 system fault: No
back-up
2 system fault:
Accelerator open-
ing angle is con-
trolled to 0%.
(high voltage of sensor or more. more than 4.9 V. 2 system fault: Accel- come
detected. Back-up:
1 system fault: No
back-up
2 system fault:
Accelerator open-
ing angle is con-
trolled to 0%.
P1345 16 Cam sensor Camshaft gear/ Key switch input Correct cam When Behavior does not ON *1
out of phase crankshaft gear voltage is 18V or pulse does not trouble change during
installing angle more. exist in crank gap occurs 7 engine running.
is out of phase, DTC P0335, P0336, position. out of 8 After engine stalls,
or damage in P0340, P0341, sam- engine will not start.
gear. P1345, or P1635 is ples. Back-up:
not detected. Engine running
CMP sensor pulse based on crank
is normal. when it is normal
Crank pulse is nor- After engine stops:
mal. Unable to identify
cylinder (unable to
restart)
P1625 416 Main relay sys- Open/ground Key switch input Main relay system Approx. Engine does not ON *2
tem fault (Not short circuit in voltage is 18V or voltage is 1V or 1.5 sec. start.
enter) harness, relay more. less with main Back-up:
OFF anchoring DTC P1630 is not relay coil output Fail-safe process
detected. ON. will not be carried
3 seconds or more out
has elapsed after key
switch ON.
Main relay drive
indication ON
Harness +B DTC P1625 or Relay does not Approx. Vehicle power sup- ON *1
short, relay ON P0606 is not cut off despite of 5 sec. ply cannot be shut
anchoring detected. main relay coil off.
output OFF indi- Back-up:
cation. Fail-safe process
will not be carried
out
P1630 36 A/D conver- A/D conver- A/D conversion Immedi- Output lowering, ON *2
sion fault sion fault failure ately Black smoke emitted
Back-up:
Analog sensor sys-
tem default pro-
cessing

Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
psi})
Fault Recov
Diag-
lamp
period failure
P1631 55 Voltage fault in Power supply DTC P1630 is not Key switch power Approx. Accelerator opening ON *2
5-V power sup- wiring short to detected. supply voltage is 0.5 sec. angle is controlled to
ply 1 sensor, or Battery voltage is 5.5V or more, or 0%.
breakage in between 16V 32V 4.5V or less. Back-up:
element/circuit Same as accelera-
for power sup- tor sensor fault
ply regulation
inside ECM.
P1632 55 Voltage fault in Power supply DTC P1630 is not Key switch power Approx. Due to back-up ON *2
5-V power sup- wiring short to detected. supply voltage is 0.5 sec. equivalent to 2000 m
ply 2 sensor, or Battery voltage is 5.5V or more, or (6562 ft)
breakage in between 16V 32V 4.5V or less. Black smoke emit-
element/circuit ted at high altitude
for power sup- Back-up:
ply regulation Same as barometric
inside ECM. pressure and intake
air temperature
sensor fault
P1633 55 Voltage fault in Power supply DTC P1630 is not Key switch power Approx. At normal tempera- ON *2
5-V power sup- wiring short to detected. supply voltage is 0.5 sec. ture: Black smoke
ply 3 sensor, or Battery voltage is 5.5V or more, or emission, greater
breakage in between 16V 32V 4.5V or less. engine combustion
element/circuit noise possible.
for power sup- During idling at low
ply regulation atmospheric temper-
inside ECM. atures: Rough idling,
engine stall, white
smoke emission pos-
sible.
Back-up:
Same as coolant
temperature, fuel
temperature, and oil
pressure sensor
fault
P1634 55 Voltage fault in Power supply DTC P1630 is not Key switch power Approx. Black smoke emitted ON *2
5-V power sup- wiring short to detected. supply voltage is 0.5 sec. Back-up:
ply 4 sensor, or Battery voltage is 5.5V or more, or Same as boost
breakage in between 16V 32V 4.5V or less. pressure and boost
element/circuit temperature sen-
for power sup- sor fault
ply regulation
inside ECM.
P1635 55 Voltage fault in Power supply DTC P1630 is not Key switch power Approx. Output weakening or ON *2
5-V power sup- wiring short to detected. supply voltage is 0.5 sec. engine stall is possi-
ply 5 sensor, or Battery voltage is 5.5V or more, or ble and exhaust gas
breakage in between 16V 32V 4.5V or less. is effected
element/circuit Back-up:
for power sup- Same as rail pres-
ply regulation sure sensor fault
inside ECM. and EGR position
sensor fault
U2104 84 CAN Bus fault CAN communi- Key switch input Bus-off is At 3 sec. Running at the speci- ON *3
cation fault voltage is 20 V or detected. continu- fied engine speed
more. ously 15t: 1900 rpm
12t: 1700 rpm
Back-up:
Running at the
specified engine
speed
15t: 1900 rpm
12t: 1700 rpm
Fault Recov
Diag-
lamp
period failure
U2104 84 CAN Bus fault CAN communi- Key switch input Bus-off is At 3 sec. Set to idle speed. ON *3
cation fault voltage is 20 V or detected. continu- Back-up:
more. ously Switch to the accel-
erator sensor input
operation
U2106 85 CAN timeout CAN communi- DTC U2104 is not CAN data recep- At 1 sec. Running at the speci- ON *3
fault cation fault detected. tion does not continu- fied engine speed
Key switch input complete at a set ously 15t: 1900 rpm
voltage is 20 V or time. 12t: 1700 rpm
more. Back-up:
Running at the
specified engine
speed
15t: 1900 rpm
12t: 1700 rpm
U2106 85 CAN timeout CAN communi- DTC U2104 is not CAN data recep- At 1 sec. Set to idle speed. ON *3
fault cation fault detected. tion does not continu- Back-up:
Key switch input complete at a set ously Switches to the
voltage is 20 V or time. accelerator sensor
more. input operation.
About recovery from failure *2

There are three modes for recovery from failure. When the DTC has recovered to normal condition in
To clear the trouble displayed on the monitor of the the ignition cycle that the DTC is detected, the diagno-
machine, one more ignition cycle may be needed after sis lamp and back up mode will also be recovered.
the following ignition cycle. 1 2
*1
Even if the DTC has restored normally, the diagnosis Key ON
lamp and back-up mode are not restored in the ignition switch
and
cycle that the DTC is detected. After turning the key Engine
OFF
run
switch OFF, DTC diagnosis is performed when the
vehicle starts again. If it is judged as normal, everything
will be recovered to normal from the next ignition cycle.
ON
1 2 3 Diag
lamp
OFF
Key ON
switch
and
Engine
run OFF
ON
Back-up
mode
OFF
ON
Diag
lamp TSWG0166
OFF Name
1. DTC is detected.
2. Returned to normal.
ON
Back-up
mode
OFF
TSWG0165
Name
1. DTC is detected.
2. Repair and inspection
*3 Sumit- ISUZU DTC description Trou
When the DTC has recovered to normal in the ignition omo P Code ble
cycle that the DTC is detected, the back-up mode will (S.H.I.) dis-
be recovered normally, but the diagnosis lamp does not Construc- play
go off. tion on
Machin- moni
1 2 ery Man- tor
ufacturing
Key ON Co., Ltd.
switch
and E Code
Enigne
run OFF E0112 P0112 Intake air temperature sensor

circuit low input
E0113 P0113 Intake air temperature sensor

ON circuit high input
Diag
lamp E0117 P0117 Engine coolant temperature

OFF sensor low input
E0118 P0118 Engine coolant temperature

sensor input is high.
ON
E0182 P0182 Fuel temperature sensor cir-
Back-up
mode cuit low input
OFF
E0183 P0183 Fuel temperature sensor cir-

TSWG0207 cuit high input
Name E0192 P0192 Common rail pressure sen-

1. DTC is detected. sor circuit low input
E0193 P0193 Common rail pressure sen-

sor circuit high input
DTC mapping table E0201 P0201 No. 1 injector injector cir-

cuit fault
Sumitomo (S.H.I.) Construction Machinery Manu-
facturing Co., Ltd. E0202 P0202 No. 2 injector injector cir-

cuit fault
Sumit- ISUZU DTC description Trou
E0203 P0203 No. 3 injector injector cir-
omo P Code ble
cuit fault
(S.H.I.) dis-
Construc- play E0204 P0204 No. 4 injector injector cir-
tion on
cuit fault
Machin- moni
ery Man- tor E0219 P0219 Overrun
ufacturing E0237 P0237 Turbocharger boost sensor
Co., Ltd.
circuit low input
E Code
E0238 P0238 Turbocharger boost sensor
E0087 P0087 Common rail pressure low
circuit high input
pressure fault (No pressure
feed in supply pump) E0335 P0335 Crankshaft position sensor

circuit fault
E0088 P0088 Common rail pressure abnor-
E0335 P0336 Crankshaft position sensor
mally high (1st or 2nd stage)
fault
E0089 P0089 Common rail pressure fault
(Excessive pressure feed in E0340 P0340 Camshaft position sensor cir-

supply pump) cuit fault
E0090 P0090 Common rail pressure con- E0340 P0341 Camshaft position sensor

trol adjusting valve circuit fault
fault E0380 P0380 Glow relay circuit fault
E0107 P0107 Barometric pressure sensor E0487 P0487 EGR valve BLDC position

circuit low input circuit fault
E0108 P0108 Barometric pressure sensor E0488 P0488 EGR valve fault

circuit high input
Sumit- ISUZU DTC description Trou Sumit- ISUZU DTC description Trou
omo P Code ble omo P Code ble
(S.H.I.) dis- (S.H.I.) dis-
Construc- play Construc- play
tion on tion on
Machin- moni Machin- moni
ery Man- tor ery Man- tor
ufacturing ufacturing
Co., Ltd. Co., Ltd.
E Code E Code
E0522 P0522 Oil pressure circuit open cir- E1632 P1632 5V #2 circuit fault

cuit
E1633 P1633 5V #3 circuit fault
E0523 P0523 Oil pressure circuit short cir-
cuit
E0601 P0601 ROM fault
E2104 U2104 CAN communication fault
E0603 P0603 EEPROM fault
E2106 U2106 Communication fault with
E0606 P0606 ECM internal trouble (CPU
TCM (Transmission control
fault)
module)
E0606 P0606 CPU monitoring IC fault
E0611 P0611 EDU charge circuit 1 low volt- Hitachi Construction Machinery Co., Ltd.

age
SPN FMI P Code DTC description Trou
E0612 P0612 EDU charge circuit 2 low volt- ble

age dis-
E1093 P1093 Fuel leakage (large amount) play
on
E1095 P1095 Pressure limiter is operated. moni
tor
E1112 P1112 Boost temperature sensor
short circuit 1239 1 P0087 No pump pressure

feed (fuel leakage)
E1113 P1113 Boost temperature sensor

open circuit 157 0 P0088 Common rail pressure

fault (1st stage)
E1173 P1173 Overheat
157 0 P0088 Common rail pressure
E1261 P1261 COMMON1 (Harness or
fault (2nd stage)
injector harness)
E1262 P1262 COMMON2 (Harness or
fault (Excessive pres-
injector harness) circuit fault
sure feed in pump)
E1271 P1271 Accelerator sensor 1 2
1347 0 P0090 SCV drive system
positional correlation fault
open circuit, +B short
E1277 P1277 Accelerator sensor 1 low or ground short

input
108 3 P0107 Barometric pressure
E1278 P1278 Accelerator sensor 1 high sensor fault (low volt-

input age fault)
E1282 P1282 Accelerator sensor 2 low 108 4 P0108 Barometric pressure

input sensor fault (high volt-
age fault)
E1283 P1283 Accelerator sensor 2 high

input 172 4 P0112 Intake air temperature
sensor fault (low volt-
E1345 P1345 Injection pump Camshaft
age fault)
positional correlation fault
172 3 P0113 Intake air temperature
E1625 P1625 Main relay circuit stuck open
sensor fault (high volt-
or stuck closed
age fault)
E1630 P1630 Analog/digital signal conver-
110 4 P0117 Engine coolant tem-
sion fault
perature sensor fault
E1631 P1631 5V #1 circuit fault (low voltage fault)
SPN FMI P Code DTC description Trou SPN FMI P Code DTC description Trou
ble ble
dis- dis-
play play
on on
moni moni
tor tor
110 3 P0118 Engine coolant tem- 100 3 P0522 Engine oil pressure
perature sensor fault sensor fault (low volt-
(high voltage fault) age fault)
174 4 P0182 Fuel temperature sen- 100 4 P0523 Engine oil pressure
sor fault (low voltage sensor fault (high volt-
fault) age fault)
174 3 P0183 Fuel temperature sen- 628 2 P0601 ROM fault
sor fault (high voltage
10013 2 P0603 EEPROM fault
fault)
1077 2 P0606 CPU monitoring IC
fault
sensor fault (low volt-
age fault) 10007 2 P0606 CPU fault
157 3 P0193 Common rail pressure 10005 1 P0611 Charge circuit fault

sensor fault (high volt- (bank 1)
age fault)
10006 1 P0612 Charge circuit fault
651 3 P0201 Open circuit in injec-
(bank 2)
tion nozzle #1 drive
system 987 3 P0650 Check engine lamp

fault
652 3 P0202 Open circuit in injec-
tion nozzle #2 drive 1239 1 P1093 No pump pressure

system feed (fuel leakage)
653 3 P0203 Open circuit in injec- 633 7 P1095 Pressure limiter open
tion nozzle #3 drive 105 4 P1112 Boost temperature
system sensor fault (low volt-
654 3 P0204 Open circuit in injec- age fault)
tion nozzle #4 drive 105 3 P1113 Boost temperature
system sensor fault (high volt-
190 0 P0219 Overrun age fault)
102 3 P0237 Boost pressure sen- 110 0 P1173 Overheat

sor fault (low voltage 10003 2 P1261 Injection nozzle com-
fault) mon 1 drive system
102 4 P0238 Boost pressure sen- fault
sor fault (high voltage 10004 2 P1262 Injection nozzle com-
fault) mon 2 drive system
723 2 P0335 Crank sensor fault (no fault

signal) 91 2 P1271 Accelerator sensor 1-

723 2 P0336 Crank sensor fault 2 comparison fault

(signal fault) 91 3 P1277 Accelerator sensor 1
636 2 P0340 Cam sensor fault (no fault (low voltage
fault)
signal)
636 2 P0341 Cam sensor fault (sig- 91 4 P1278 Accelerator sensor 1
fault (high voltage
nal fault)
fault)
10001 3 P0487 EGR position fault
(Brushless specifica- 91 3 P1282 Accelerator sensor 2
tion) fault (low voltage
fault)
10002 2 P0488 EGR valve control

fault
SPN FMI P Code DTC description Trou

ble
dis-
play
on
moni
tor
91 4 P1283 Accelerator sensor 2
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

power supply 5
639 2 U2104 CAN Bus fault
639 3 U2106 CAN timeout fault

Compliant with ISUZU P Code
DTC: P0087 (Flash code 227) Common rail low pressure fault (No pressure feed in supply
pump)
3
1
4
5
TSJJ0103
Name
4. Pre-filter
Engine control
module (ECM)
EGR EGR EGR

5V
B+ B+ B+
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8

18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
0.5 0.5 0.5

L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80
2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113

V
W U
TSJJ0038
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
Engine blow up fault
Black smoke emitted
Excessive output is possible.
Fuel system filter Action taken when DTC is set
Trouble is displayed on the monitor of the machine* or
4 diagnosis lamp comes on. (* Nothing is displayed
3 depending on the machine manufacturer.)
Back-up mode
5 Target RP upper limit (80 MPa {11603 psi})

Refer to 1E-297, List of Diagnostic Trouble Codes
2
and About recovery from failure in this section for
recovery from failure.
The conditions to clear the MIL/DTC

The present trouble turns to history trouble when
1
TSJJ0137
dition (recovery from failure).
Name The check engine lamp will go off after the code
1. Fuel pump strainer turns to history trouble and the key switch is turned
2. Pre-fuel filter OFF then ON again.
3. Electromagnetic pump filter Using the scan tool, or memory clear switch and
4. Main fuel filter diagnostic switch operation enables to clear DTCs.
5. Gauze filter
Diagnostic aid
Filter clogging in the fuel system may establish the Followings are suspected as the cause.
DTC set condition. Check as required. Injector internal trouble
Supply pump internal trouble
Preconditions when DTC is set
Improper operation due to foreign matter etc. in the
900 rpm or more SCV which is installed in the supply pump.
Air in the fuel system
DTC set condition
Fuel system pipe fault (fuel leakage, clogging,
Actual rail pressure is 15 MPa (2176 psi) or less for 3 crush, etc.)
seconds or more.
Fuel filter fault (clogging)
Fuel tank fault (clogging)
:Desired rail puressure Pressure limiter trouble (operation under specified
:Actual rail presure
pressure, degradation of sealability)
ECM trouble
Common rail pressure sensor trouble
Absolute pressure
Test description
8. If the Common rail pressure sensor displays the
50MPa(7252psi)
specified value or more when the common rail pressure
Actual 1 P1093 sensor connector is removed, the circuit beyond the
t2 > 5sec sensor is normal including ECM.
t1 > 3sec
15MPa Actual 2
(2176psi) P0087
TSJJ0111

system check, List
of Function
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
2 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 4. Go to Step 3.

Repair or replace the faulty part.
3
Check that the difference value between the com-
mon rail pressures decreases while cranking. 30 MPa (
5 4351 psi) 0
Does the common rail pressure vary as the speci- MPa (0 psi)
fied value? Go to Step 7. Go to Step 6.
Check fuel discharge.
Important:
Check that the fuel discharge on the upstream
side of the supply pump is normal.
Refer to 1E-320, Fuel discharge inspection
6 procedure, DTC: P0087 (Flash code 227) Com-
mon rail low pressure fault (No pressure feed in
supply pump), List of Diagnostic Trouble
Codes.

Check the common rail pressure.
2. Check the Common rail pressure on the data
display using a scan tool. At engine
3. Start the engine and run it at idle. stopped: Differ-
4. Check the Differential fuel rail pressure on ential pressure
the data display using a scan tool. 30 MPa (
7
4351 psi); At
5. Race it quickly for about 5 times. idling, racing:
6. Check the Differential fuel rail pressure on 5 MPa (725
the data display using a scan tool. psi)
Is each value of Fuel rail pressure (at engine

stopped, idling and racing) around the specified
value? Go to Step 10. Go to Step 8.
2. Disconnect the common rail pressure sensor
connector.
8 4.8V
4. Check the Common rail pressure sensor on
the data display using a scan tool.
Is the Common rail pressure sensor the specified


1. Check the signal circuit between common rail
pressure sensor and ECM for short circuit to
signal circuits of other sensors using breaker
box or DMM.
9
mon rail low pressure fault (No pressure feed
in supply pump), List of Diagnostic Trouble
Codes.

Check for rise of fuel level in the oil level gauge or
10 light oil odor.
Check the connection of the fuel pipe in each injec-
tor, and replace the injector if oil leakage is con-
firmed.
11 Note:
service manual.

Check the injector.
1. Clear the DTC.
clear DTCs.
3. Select the Actuator test from the menu.
12
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 13. Go to Step 14.
Replace the injector in the cylinder of which engine
sound did not change when it is stopped.
Note:
service manual.


necessary.
15 Note:
Is the rewriting completed? Go to Step 18. Go to Step 16.

Replace the ECM.
Note:

Replace the common rail (common rail pressure
17 sensor).
Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
clear DTCs.
seconds.
4. Test drive with the Preconditions when DTC is
set.
5. Check the DTC.
Is DTC P0087 detected? Go to Step 2. Go to Step 19.

19 Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
Important:
20 procedure, DTC: P0087 (Flash code 227) Com-
mon rail low pressure fault (No pressure feed in
supply pump), List of Diagnostic Trouble
Codes.


connector.
21 4.8V
4. Measure the voltage between the common rail
pressure sensor connector power supply ter-
minal and the ground.
box or DMM.
22
mon rail low pressure fault (No pressure feed
in supply pump), List of Diagnostic Trouble
Codes.

23 light oil odor.
firmed.
24 Note:
service manual.

Perform the injection balance test.
Use the EMPSIII or CAN communication scan tool
to stop injection from the injector, and check the
25 change in engine vibration and engine sound.

About common rail pressure sensor Fuel discharge inspection procedure
Check the fuel discharge on the fuel system upstream
side in the following procedure.
pump.
3. Check if fuel is discharged from the fuel line.
If fuel is discharged, go to 4. Check for air
mixed in fuel.
electromagnetic pump.
3 2 1
5
4
3
TSWG0055
Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply

sensor 1
TSHK0164
(V)
4.2 Name
1. Supply pump
2. Fuel tank
3. Pre-fuel filter
5. Fuel filter
6. Supply pump inlet
0 200(29008)
MPa(psi)
TSWG0201
4. Check for air mixed in fuel 5. Check the electromagnetic pump
Connect a clear pipe to fuel line, and check that no Disconnect the pipe from the outlet side of the
air is mixed in discharged fuel. electromagnetic pump, and activate the pump.
If air is mixed in fuel, determine and repair the If fuel is discharged from the electromagnetic
point, where the air enters, on the upstream pump, check the lines of other than this pump
side of the low pressure line. for faults.
If no air is mixed in fuel, fault inside the supply If no fuel is discharged from the electromag-
pump may be suspected. Replace the SCV. If netic pump, check the pump according to Elec-
this does not correct the fault, replace the sup- tromagnetic pump inspection procedure.
ply pump.
Note:
5
Engine component location diagram, Engine Con- 4
trol System in this section for the SCV replacement
3
procedure.
Refer to Engine section in the service manual for
replacing the supply pump. 6
6
5
4
1
3 2
TSHK0167
Name
1. Supply pump
2. Fuel tank
3. Pre-fuel filter
5. Fuel filter
1 6. Electromagnetic pump outlet
2
TSHK0165
Name 1. Turn the key switch to ON, and check for pulsation
1. Supply pump in the fuel hose.
2. Fuel tank It is normal if pulsation exists.
3. Pre-fuel filter
5. Fuel filter
6. Clear pipe
machine-side harness. Repair the faulty part,
and check again from Step 1.
replace the pump.
1
2
Box.
TSHK0106
Name
2. + terminal
3. - terminal

with your mouth.
inate sticking.
Name
1. Breaker box
2. DMM
2
TSHK0107
Name
1. Fuel inlet port
2. Fuel outlet port

Step 1.
9, 22 Short circuit to Voltage mea- Disconnect the 82 GND 0V 1 V or more
other signal cir- surement sensor connector. 90 GND
cuit Key switch ON
DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage)
3
1
4
5
TSJJ0103
Name
4. Pre-filter
Engine control
module (ECM)
EGR EGR EGR

5V
B+ B+ B+
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8

18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
0.5 0.5 0.5

L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80
2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113

V
W U
TSJJ0038
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
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-297, 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
OFF then ON again.
Using the scan tool, or memory clear switch and
Common rail
diagnostic switch operation enables to clear DTCs.

pressure
T>1sec=P1095
Diagnostic aid
200 MPa
(29008psi)
may 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
Action taken when DTC is set
Trouble is displayed on the monitor of the Damage of connector lock
is displayed depending on the machine manufac- Poor contact between terminal and wire
turer.) 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-
Entry of foreign matter into the SCV of the supply
pump may cause improper operation, and the fuel
pressure may overshoot. In this case, the SCV
needs to be replaced.

system check, List
of Function

2. Check the DTC.
3. Are the fuel-related parts just replaced?
Important:
2 Air bleeding may not be performed sufficiently
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
pressure 5
4 3. Check the Differential fuel rail pressure on
MPa (725 psi)
(at idle)
Is Differential fuel rail pressure within the speci-
1. Check if the common rail pressure shows
unstable value using a scan tool.
2. If the trouble is detected, the SCV may need to
5 be replaced. Remember this, and go to the
next step.

1. Perform Common rail pressure test using a
scan tool.
2. Check the common rail pressure follow-up.
6 3. If the trouble is detected, the SCV may need to
be replaced. Remember this, and go to the
next step.

1. Race the engine on a level surface, and check
if overshooting occur during pressure rising.
7 be replaced. Remember this.
Was at least one trouble detected in the steps 5 Go to Diagnostic

7? Go to Step 8. aid.
Replace the SCV.
Note:
8 Engine component location diagram, Engine Con-
trol System in this section for the SCV replace-
ment procedure.
Is the symptom improved? Go to Step 12. Go to Step 11.

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.
9
3. Check for foreign matter in the fuel tank.
4. If the trouble is detected, repair as required.


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.

Replace the supply pump.
Note:
service manual.

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

Check if other DTC is detected.
13 Go to each DTC
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.
14
3. Check for foreign matter in the fuel tank.

1. Replace the SCV.
Note:
Engine component location diagram, Engine Con-
15 trol System in this section for the SCV replace-
ment procedure.
2. Check the DTC.

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.
About common rail pressure sensor
3 2 1
TSWG0055
Name
1. Sensor ground
2. Sensor signal

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)
3
1
4
5
TSJJ0103
Name
4. Pre-filter
Engine control
module (ECM)
EGR EGR EGR

5V
B+ B+ B+
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8

18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
0.5 0.5 0.5

L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80
2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113

V
W U
TSJJ0038
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
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 60C (140F) 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 cuin/sec) or less.
DTC set condition
Main trouble symptom Actual rail pressure is 40 MPa (5802 psi) or 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, the followings
machine* or diagnosis lamp comes on. (* Nothing may be the cause.
is displayed depending on the machine manufac- Improper connection of harness connector
turer.)
Back-up mode Worn harness cladding
Target RP upper limit (80 MPa {11603 psi}) causes.
ECM connector
Refer to 1E-297, 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.

system check, List
of Function
2. Check the DTC.
2 Is any of the following DTC detected? DTC P0089,

P0090, P0192, P0193, P0201, P0202, P0203,
P0204, P0611, P0612, P1095, P1261, P1262 or Go to the relevant
P1635. DTC detected. Go to Step 3.
seconds.
2. Start the engine. Differential
4 3. Check the Differential fuel rail pressure on pressure 5
the data display using a 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
4. Check the Differential fuel rail pressure on
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.

Replace the SCV.
Note:
ment procedure.

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

11 Go to each 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
sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
(V) the wiring of sensor connector.
4.2 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.
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
The suction control valve (SCV) controls the fuel feed
pressure amount to the common rail. Once the SCV
installed to the supply pump receives the signal (volt-
age), the SCV closes the valve and pressure-feeds fuel
200MPa
from the supply pump to the common rail. The engine (29008psi)
control module (ECM) operates the SCV to adjust the
common rail pressure.

If the engine starts with the signal (voltage) is not sent
to the SCV, common rail pressure reaches 200MPa 50MPa
(29008psi) due to the normal open structure of the (7252psi)
SCV. Common rail pressure becomes high pressure
status (for approx. 2 sec. at cranking) and the pressure t1 = 2sec t
limiter opens, then common rail pressure decreases to
50MPa (7252psi). Output is lowering since common rail
pressure is limited. TSHK0170
Because the pressure limiter opens, the output lowers The conditions to clear the MIL/DTC
and the engine can be operated only at low load condi-
tion. If short circuit occurs, the SCV will close thus the
output lowers.
Preconditions when DTC is set The diagnosis lamp will go off after the code turns
Main relay power supply voltage is 18V or more. OFF then ON again.
DTC P1630 is not detected. Using the scan tool, or memory clear switch and
SCV drive duty is between 10% and 90%. diagnostic switch operation enables to clear DTCs.
DTC set condition Diagnostic aid

When the SCV drive current becomes above 2400 If the intermittent trouble is suspected, the followings
mA for 1.5 seconds or more. may be the cause.
When the SCV drive current becomes 50 mA or Improper connection of harness connector
less for 1.5 seconds or more. Defective harness routing
When the difference between target and actual Worn harness cladding
current becomes 1000 mA for 1.5 seconds or
more.
causes.
Trouble is displayed on the monitor of the ECM connector
turer.) Unmatched terminals are fitted.
Back-up mode Poor contact between terminal and wire
Limited injection amount 3 (multi-injection stopped) Damaged harness
Target RP upper limit (80 MPa {11603 psi}) Visually check the harness for damage.
Recovery from failure display while moving the connector and the har-
Refer to 1E-297, List of Diagnostic Trouble Codes ness which are related to the sensor. The varia-
and About recovery from failure in this section for tion of the display indicates the faulty part.

system check, List
of Function
3 3. Check for SCV F/B on the data display using 50mA
a 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 fault 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 ;
2. Remove the harness from the SCV. Each terminal
6
3. Measure the resistance between the SCV con- to SCV body:
nector terminals. (at 20C
{68F})
Replace the SCV.
Note:
ment procedure.


2. Clear the DTC.
clear DTCs.
seconds.
4. Start the engine, and test drive with the Pre-
conditions when DTC is set.
5. Check the DTC.
Go to Diagnostic
Is DTC P0090 detected? Go to Step 9. aid.
necessary.
10 Note:

Replace the ECM.
Note:

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

13 Go to each DTC
About SCV Breaker box inspection procedure
Box.
TSJJ0106
Name
1. SCV
Name
1. Breaker box
2. DMM
Name
1. SCV-HI
2. SCV-LO
Step Item to be Checking Measuring condition Terminal No. Normal Abnormal

checked method value value
4 Open circuit/ Resistance Disconnect the 105 SCV terminal 5 or less 10 M 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 GND 10 M or 100 or less
ground measurement SCV connector. 113 GND more
Key switch OFF 89 GND
97 GND
5 Short circuit Resistance Disconnect the 105 89 10 M or 100 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 GND 0V 16 V or
power supply surement SCV connector. 113 GND more
circuit Key switch ON 89 GND
97 GND
Short circuit to Voltage mea- Disconnect the 105 GND 0V 1 V or more
other signal cir- surement SCV connector. 113 GND
cuit Key switch ON 89 GND
97 GND
On-board check procedure for sensors If both steps 1 and 2 are faulty, repair the har-
3 If only step 1 is faulty, replace the sensor.
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

the wiring of sensor connector.
3. Check the harness from coupling connector for
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 Intake air

position position Barometric pressure temperature
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 LOW CAN HIGH

TSJJ0039
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 Barometric pressure sensor voltage is 0.5V or less
(if the barometric pressure is low, output voltage for 5 seconds or more.
becomes low, if the barometric pressure is high, the
output voltage becomes high as well). The engine con- Action taken when DTC is set
trol module (ECM) reads this output voltage change, Trouble is displayed on the monitor of the
converting it into barometric pressure, to utilize for opti- machine* or diagnosis lamp comes on. (* Nothing
mizing the fuel injection control and for calculating the is displayed depending on the machine manufac-
relative boost pressure. turer.)
Main trouble symptom Back-up mode

Due to back-up equivalent to 2000 m (6562 ft) Barometric pressure default setting (80 kPa {11.6
Black smoke emitted at high 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
Poor contact between terminal and wire
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
If the intermittent trouble is suspected, the followings Test description
may be the cause.
Improper connection of harness connector 3. In the case of present trouble, the Barometric pres-
Defective harness routing sure sensor displays the specified value or less. If
Worn harness cladding more than the specified value, identify the cause by
Wire disconnection inside harness cladding referring to Diagnostic aid.
The following inspections are necessary to detect these 5. If the Barometric pressure sensor displays the
causes. specified value or more when terminals between the
barometric pressure sensor connector are shorted, the
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 a scan tool.
3 0.5V
3. Check the value for Barometric pressure sen-
sor using a scan tool.
Is the Barometric pressure sensor the specified Go to Diagnostic

value or less? Go to Step 4. aid.
Check the installation condition of the barometric
pressure sensor and ECM connector.
1. Check for play or looseness in the connection.
4
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 the specified


1. Check for the 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
6 Trouble Codes.
Open circuit
High resistance
required.

1. Check for the followings in the signal circuit
between ECM and barometric pressure sensor
using breaker box or DMM.
Trouble Codes.
7 Short circuit to barometric pressure sensor
ground circuit
Open circuit
High resistance
required.

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

Replace the ECM.
Note:


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

13 Go to each DTC
Is the scan tool or monitor (CAN communication)
14
available? Go to Step 15. Go to Step 16.
Check the value for barometric pressure using a
scan tool or monitor.
1. Connect the scan tool or monitor.
2. Start the engine. 127 kPa (18.4
15 psi) (error
3. Check the value for Barometric pressure
value)
using a scan tool or monitor.
Does the display of Barometric pressure show Go to Diagnostic

error value? Go to Step 16. aid.
pressure sensor and ECM connector. (Check the
barometric pressure sensor circuit for open circuit
or ground short.)
16 1. Check for disconnection, play or looseness in

the connection.
required.

circuit between ECM and barometric pressure
sensor using breaker box or DMM.
17 Trouble Codes.
Open circuit
High resistance
required.


Trouble Codes.
18 Short circuit to barometric pressure sensor
ground circuit
Open circuit
High resistance
required.
About barometric pressure sensor
1 2 3
1 2 3
TSHK0146
TSWG0058
Terminal Resistance
Name
1. Power supply 12 15 k
2. GND 32 15 k
3. Signal
Characteristics of barometric pressure sensor Breaker box inspection procedure
The output voltage of barometric pressure sensor Perform the inspection in the following procedure if
changes according to the barometric pressure. there is such an instruction to use breaker box in the
The scan tool with CAN communication displays a fixed step. After inspection, return to the diagnostic step.
value when the value exceeds the threshold voltage. Ways to measure voltage and resistance are different
Therefore, judge as it is more than the threshold value when using a breaker box.
if the value of 40 kPa (5.8 psi) or 120 kPa (17.4 psi) is Refer to 1E-194, Example of use for breaker box,
not changed. Breaker box inspection procedure, How to Use Breaker
When error occurs, error value (127 kPa {18.4 psi}) is Box.
displayed. The following illustration shows the correla-
tion between physical value and voltage displayed in
the scan tools with CAN communication.
Tech2, EMPSIII and scan tools with KW communica-
tion can display both physical value and voltage.
(V)
2.279198
1.009671
Name
1. Breaker box
40(5.8) 120(17.4) kPa(psi) 2. DMM
TSWG0205

6, 17 Open circuit/ Resistance Disconnect the 61 Sensor connector 100 or less 10 M or
high resistance measurement sensor connector. power supply terminal more
Key switch OFF
7, 18 Short circuit to Resistance Disconnect the 71 60 10 M or 100 or less
ground circuit/ measurement sensor connector. 71 GND more
ground Key switch OFF
Open circuit/ Resistance Disconnect the 71 Sensor connector 100 or less 10 M or
high resistance measurement sensor connector. signal terminal more
Key switch OFF
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 LOW CAN HIGH

TSJJ0039

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. (* Nothing
relative boost pressure. is displayed depending on the machine manufac-
turer.)
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
psi})
EGR stopped
ECM connector
Diagnostic aid
If the intermittent trouble is suspected, the followings Test description
may be the cause.
Improper connection of harness connector 3. In the case of present trouble, the Barometric pres-
Defective harness routing sure sensor displays the specified value or more. If
Worn harness cladding less than the specified value, identify the cause by
Wire disconnection inside harness cladding referring to Diagnostic aid.
The following inspections are necessary to detect these 5. If the Barometric pressure sensor displays the
causes. specified value or more when the barometric pressure
sensor connector is removed, the circuit beyond the
sensor is normal including ECM.

1 system check and
Check the value for barometric pressure sensor
using a scan tool.
3 3.8V
Is the Barometric pressure sensor the specified Go to Diagnostic

value or more? Go to Step 4. aid.
pressure sensor and ECM connector.
4
required.

connector.
5 0V
Is the Barometric pressure sensor the specified

value or less? Go to Step 8. Go to Step 6.

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
6 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 the followings in the ground circuit
Open circuit
High resistance
required.

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

Replace the ECM.
Note:


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

13 Go to each DTC
14
Check the value for barometric pressure using a
2. Start the engine. 127 kPa (18.4
15 psi) (error
3. Check the value for Barometric pressure
value)
Does the display of Barometric pressure show Go to Diagnostic

pressure sensor and ECM. (Check the barometric
pressure sensor circuit for short to +5V line or bat-
tery power supply circuit.)
required.

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


Open circuit
High resistance
required.
About barometric pressure sensor

Terminal Resistance
12 15 k
32 15 k
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.
1 2 3
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.
TSWG0058 tion can display both physical value and voltage.
Name
1. Power supply
2. GND
(V)
3. Signal
2.279198
1 2 3
1.009671
40(5.8) 120(17.4) kPa(psi)
TSWG0205
TSHK0146
Box.
Name
1. Breaker box
2. DMM

6, 17 Short circuit to Voltage mea- Disconnect the 71 GND 0V 16 V or
power supply surement sensor connector. more
circuit Key switch ON
high resistance measurement sensor connector. ground terminal more
Key switch OFF
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 LOW CAN HIGH

TSJJ0039

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 3.5 seconds
calculate the intake air temperature from the change in or 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. (* Nothing
Main trouble symptom turer.)
Not in particular
Intake air temperature default setting (at starting: Wire disconnection inside harness cladding
10C {14F}, at driving: 25C {77F}) The 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.
display while moving the connector and the har-
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 the specified value or less. If
tance. If the sensor is faulty, operationality may be more than the specified value, identify the cause by
affected. referring to Diagnostic aid.
If the intermittent trouble is suspected, the followings 5. If the Intake air temperature sensor displays the
may be the cause. specified value or more when the IAT sensor connector
Improper connection of harness connector is removed, the circuit beyond the sensor is normal
Defective harness routing including ECM.

1 system check and
Check the value for IAT sensor using a scan tool.
3 3. Check the value for Intake air temperature 0.1V
sensor using a scan tool.
Is the Intake air temperature sensor the specified Go to Diagnostic

Check the installation condition of the IAT sensor
and ECM connector.
4 2. If the fault is detected, repair or replace as
required.

2. Disconnect the IAT sensor connector.
Is the Intake air temperature sensor the specified


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
6 Trouble Codes.
Short circuit to IAT sensor ground circuit
required.

Replace the IAT sensor.
7
necessary.
9 Note:

Replace the ECM.
Note:

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

12 Go to each DTC
13

Check the value for intake air temperature using a
2. Start the engine. 214C (419F)
14
3. Check the value for Intake air temperature (error value)
Does the display of Intake air temperature show Go to Diagnostic

and ECM connector. (Check the IAT sensor circuit
for ground short.)

required.

box or DMM.
GND short, short circuit), List of Diagnostic
16 Trouble Codes.
Short circuit to IAT sensor ground circuit
required.

About IAT sensor Characteristics of intake air temperature
sensor
The output voltage of IAT sensor changes according to
the intake air.
if the value of 40C (40F) or 120C (248F) is not
changed.
When error occurs, error value 214C (419F) 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
Name
1. Signal
2. GND
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
Box.
Name
1. Breaker box
2. DMM

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 LOW CAN HIGH

TSJJ0039

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 3.5 sec-
control. If the resistance is low (temperature is high), onds 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. (* Nothing
Not in particular is displayed depending on the machine manufac-
turer.)
Intake air temperature default setting (at starting: Wire disconnection inside harness cladding
10C {14F}, at driving: 25C {77F}) The following inspections are necessary to detect these
causes.
EGR stopped
Damaged harness
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 the specified value or more. 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, the followings 5. If the Intake air temperature sensor displays the
may be the cause. specified value or less when terminals between the IAT
Improper connection of harness connector sensor connector are shorted, the circuit beyond the
Defective harness routing sensor is normal including ECM.

1 system check and
Check the value for IAT sensor using a scan tool.
Is the Intake air temperature sensor the specified Go to Diagnostic

and ECM connector.
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 the specified

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,
6 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.
open circuit or short to power supply circuit),
7 List of Diagnostic Trouble Codes.
Open circuit
High resistance
required.

box or DMM.
Open circuit
High resistance
required.

Replace the IAT sensor.
9

necessary.
11 Note:

Replace the ECM.
Note:

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

14 Go to each DTC
15
Check the value for intake air temperature using a
3. Check the value for Intake air temperature
using a scan tool or monitor. 214C (419F)
16
(error value)
4. Display of intake air temperature is 214C
(419F) due to back-up mode after fault judg-
ment.
Does the display of Intake air temperature show Go to Diagnostic


and ECM connector.
required.

1. Check the signal circuit between ECM and IAT
breaker box or DMM.
18 open circuit or short to power supply circuit),
Important:
If the IAT sensor circuit is shorted to the power

box or DMM.
Open circuit
High resistance
required.

box or DMM.
Open circuit
High resistance
required.

About IAT sensor Characteristics of intake air temperature
sensor
The output voltage of IAT sensor changes according to
the intake air.
changed.
(V)
4.8691
Name
1. Signal
2. GND
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
Box.
Name
1. Breaker box
2. DMM

Key switch OFF
Key switch OFF
DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault,
GND short, short circuit)

5V
Engine coolant Vcc

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
0.75 0.75 0.75
B/Y L/Y W/B
Pulse 0.75 0.75 0.75 0.75

matching Y/G B/Y Y/G B/Y
box 2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
Engine
coolant
temperature
pressure sensor
A
0.75
R
4 H-6 37 E-57 18 E-57

Vehicle
speed sensor
A
Meter
Machine
control
unit
coolant
temperature
gauge
Machine trouble
diagnosis monitor
TSJJ0036
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 3.5 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, the followings
may be the cause.
machine* or diagnosis lamp comes on. (* Nothing Improper connection of harness connector
is displayed depending on the machine manufac- Defective harness routing
turer.) Worn harness cladding
Back-up mode
Coolant temperature default setting (at starting: causes.
20C {4F}, at running: 80C {176F}) Improper connection of harness connector and
EGR stopped ECM connector
Refer to 1E-297, List of Diagnostic Trouble Codes Damage of connector lock
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 the specified value or more.
After starting the engine, the thermostat begins to
In this case, identify the cause by referring to Diagnos-
open when the engine coolant temperature rises
tic aid.
(85C {185F}), and the engine coolant tempera-
5. If the Engine coolant temperature sensor displays
ture is stabilized.
the specified value or more when the ECT sensor con-
To make sure the correct performance of the ECT nector is removed, the circuit beyond the sensor is nor-
sensor, check with various temperatures using the mal including ECM.
reckoner table between temperature and resis-
tance. If the sensor is faulty, operationality may be
affected.

1 system check and
Check the value for ECT sensor using a scan tool.
3 3. Check the value for Engine coolant tempera- 0.1V
ture sensor using a scan tool.
Is the Engine coolant temperature sensor the Go to Diagnostic

specified value or less? Go to Step 4. aid.
Check the installation condition of the ECT sensor,
ECM and coupling connector.
4
required.


2. Disconnect the ECT sensor connector.
Is the Engine coolant temperature sensor the

specified value or more? 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-
cuit), List of Diagnostic Trouble Codes.
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.
9 Note:

Replace the ECM.
Note:


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

12 Go to each DTC
13
Check the value for engine coolant temperature
3. Check the value for Engine coolant tempera- 214C (419F)
14
ture using a scan tool or monitor. Display of (error value)
engine coolant temperature is 214C (419F)
due to back-up mode after fault judgment.
Does the display of Engine coolant temperature

show error value? Go to Step 15. Go to Step 11.
required.

box or DMM.
coolant temperature sensor fault (low voltage
fault, GND short, short circuit), List of Diagnos-
tic Trouble Codes.
Note:
16 P0117 (Flash code 23) Engine coolant temperature
sensor fault (low voltage fault, GND short, short cir-
cuit), List of Diagnostic Trouble Codes.
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 Refer to 1E-194, Example of use for breaker box,
The output voltage of ECT sensor changes according Breaker box inspection procedure, How to Use Breaker
to the engine coolant temperature. The scan tool with Box.
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
40C (40F) or 120C (248F) is not changed.
played.
(V)
4.8691
Name
1. Breaker box
2. DMM
0.1797
-40 120
(-40) (248) F
TSWG0180

On-board check procedure for sensors
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
Engine coolant Vcc

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
0.75 0.75 0.75
B/Y L/Y W/B
Pulse 0.75 0.75 0.75 0.75

box 2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
Engine
coolant
temperature
pressure sensor
A
0.75
R
4 H-6 37 E-57 18 E-57

Vehicle
speed sensor
A
Meter
Machine
control
unit
coolant
temperature
gauge
Machine trouble
diagnosis monitor
TSJJ0036

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 3.5 sec-
onds or more.
Action taken when DTC is set If the intermittent trouble is suspected, the followings
may be the cause.
machine* or diagnosis lamp comes on. (* Nothing Improper connection of harness connector
is displayed depending on the machine manufac- Defective harness routing
turer.) Worn harness cladding
Back-up mode
Coolant temperature default setting (at starting: causes.
20C {4F}, at running: 80C {176F}) Improper connection of harness connector and
EGR stopped ECM connector
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-
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 the specified value or more.
(85C {185F}), and the engine coolant tempera- If less than the specified value, identify the cause by
ture is stabilized. referring to Diagnostic aid.
To make sure the correct performance of the ECT
the specified value or less when terminals between the
sensor, check with various temperatures using the
ECT sensor connector are shorted, the circuit beyond
reckoner table between temperature and resis-
the sensor is normal including ECM.
tance. If the sensor is faulty, operationality may be
affected.

1 system check and
Check the value for ECT sensor using a scan tool.
Is the Engine coolant temperature sensor the Go to Diagnostic

specified value or more? 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-

specified value or less? Go to Step 9. Go to Step 6.
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-378,
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:
7 On-board check procedure for sensors, DTC:
Open circuit
High resistance
required.


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

9
necessary.
11 Note:

Replace the ECM.
Note:


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

14 Go to each DTC
15
Check the value for engine coolant temperature
3. Check the value for Engine coolant tempera-
214C (419F)
16 ture using a scan tool or monitor.
(error value)
Display of engine coolant temperature is
214C (419F) due to back-up mode after fault
judgment.
Does the display of Engine coolant temperature Go to Diagnostic

show error value? Go to Step 17. aid.
17
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
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 Refer to 1E-194, Example of use for breaker box,
The output voltage of ECT sensor changes according Breaker box inspection procedure, How to Use Breaker
to the engine coolant temperature. The scan tool with Box.
CAN communication displays a fixed value when the
value exceeds the threshold voltage. Therefore, judge
played.
(V)
4.7441
Name
1. Breaker box
2. DMM
0.2129
-40 120
(-40) (248) F
TSWG0181

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

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

5V
Engine coolant Vcc

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
0.75 0.75 0.75
B/Y L/Y W/B
Pulse 0.75 0.75 0.75 0.75

box 2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
Engine
coolant
temperature
pressure sensor
A
0.75
R
4 H-6 37 E-57 18 E-57

Vehicle
speed sensor
A
Meter
Machine
control
unit
coolant
temperature
gauge
Machine trouble
diagnosis monitor
TSJJ0036

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 3.5 seconds
ECM energizes 5 V to the FT sensor through the pull or 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. (* Nothing
low), the voltage becomes high. is displayed depending on the machine manufac-
turer.)
Not in particular Back-up mode
Fuel temperature default setting (at starting: 20C
{4F}, at running: 70C {158F})
Recovery from failure The 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
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
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-
When the engine cold (before starting engine), tion of the display indicates the faulty part.
check if the temperatures of the FT sensor and IAT
sensor are close.
Test description
may be the cause. Numbers below indicate step numbers in the chart.
3. In case of present trouble, the Fuel temperature
sensor displays the specified value or more. In this
Defective harness routing case, identify the cause by referring to Diagnostic aid.
Worn harness cladding 5. If the Fuel temperature sensor displays the speci-
Wire disconnection inside harness cladding fied value or more when the FT sensor connector is
removed, the circuit beyond the sensor is normal
including ECM.

1 system check and
Check the value for FT sensor using a scan tool.
3 3. Check the value for Fuel temperature sensor 0.1V
using a scan tool.
Is the Fuel temperature sensor the specified Go to Diagnostic

Check for installation condition of the FT sensor,
4
required.

2. Disconnect the FT sensor connector.
using a scan tool.
Is the Fuel temperature sensor the specified


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-
tic Trouble Codes.
Short circuit to FT sensor ground circuit
required.

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

Replace the ECM.
Note:

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


12 Go to each DTC
13
Check the value for fuel temperature using a scan
tool or monitor.
3. Check the value for Fuel temperature using a 214C (419F)
14
scan tool or monitor. (error value)
Display of fuel temperature is 214C (419F)
Does the display of Fuel temperature show error Go to Diagnostic

value? Go to Step 15. aid.
required.

box or DMM.
GND short), List of Diagnostic Trouble Codes.
Note:
fault (low voltage fault, GND short), List of Diagnos-
tic Trouble Codes.
Short circuit to FT sensor ground circuit
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 when using a breaker box.
The output voltage of FT sensor changes according to Refer to 1E-194, Example of use for breaker box,
the fuel temperature. The scan tool with CAN commu- Breaker box inspection procedure, How to Use Breaker
nication displays a fixed value when the value exceeds Box.
the threshold voltage. Therefore, judge as it is more
than the threshold value if the value of 30C (22F)
or 120C (248F) is not changed.
played.
(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: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open
circuit or short to power supply circuit)

5V
Engine coolant Vcc

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
0.75 0.75 0.75
B/Y L/Y W/B
Pulse 0.75 0.75 0.75 0.75

box 2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
Engine
coolant
temperature
pressure sensor
A
0.75
R
4 H-6 37 E-57 18 E-57

Vehicle
speed sensor
A
Meter
Machine
control
unit
coolant
temperature
gauge
Machine trouble
diagnosis monitor
TSJJ0036

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 3.5 sec-
the change in voltage, to utilize for supply control etc. If onds 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
Main trouble symptom is displayed depending on the machine manufac-
Not in particular turer.)
Back-up mode Wire disconnection inside harness cladding
Fuel temperature default setting (at starting: 20C
causes.
{4F}, at running: 70C {158F})
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 the specified value or more. In this
If the intermittent trouble is suspected, the followings case, identify the cause by referring to Diagnostic aid.
may be the cause. 5. If the Fuel temperature sensor displays the speci-
Improper connection of harness connector fied value or less when terminals between the FT sen-
Defective harness routing sor connector are shorted, the circuit beyond the
Worn harness cladding sensor is normal including ECM.

1 system check and
Check the value for FT sensor using a scan tool.
using a scan tool.
Is the Fuel temperature sensor the specified 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 a scan tool.
Is the Fuel temperature sensor the specified


1. Check the signal circuit between ECM and FT
breaker box or DMM.
Note:
fault (high voltage fault, open circuit or short to
power supply circuit), List of Diagnostic Trouble
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.
11 Note:

Replace the ECM.
Note:


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

14 Go to each DTC
15
Check the value for fuel temperature using a scan
tool or monitor.
3. Check the value for Fuel temperature using a 214C (419F)
16
scan tool or monitor. (error value)
Display of fuel temperature is 214C (419F)
Does the display of Fuel temperature show error Go to Diagnostic

required.

1. Check the signal circuit between ECM and FT
breaker box or DMM.
Note:
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 when using a breaker box.
The output voltage of FT sensor changes according to Refer to 1E-194, Example of use for breaker box,
the fuel temperature. The scan tool with CAN commu- Breaker box inspection procedure, How to Use Breaker
nication displays a fixed value when the value exceeds Box.
the threshold voltage.
changed.
(V)
4.5195
Name
1. Breaker box
2. DMM
0.1973
-30 120
(-22) (248) F
TSWG0203

Key switch OFF
Key switch OFF
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)
EGR EGR EGR

5V
B+ B+ B+
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8

18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
0.5 0.5 0.5

L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80
2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113

V
W U
TSJJ0038

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
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.
and ground in the common rail pressure sensor, which
turer.)
Rail pressure feedback control stopped
Limited injection amount 2 (multi-injection stopped) causes.
EGR stopped Improper connection of harness connector and
Actual rail pressure default setting (80 Mpa {11603 ECM connector
psi}) Poor connection of terminal from connector
and About recovery from failure in this section for Poor contact between terminal and wire
recovery from failure. Damaged harness
The conditions to clear the MIL/DTC Check the relevant items on the scan tool data
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.
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. In case of present trouble, the Common rail pres-
diagnostic switch operation enables to clear DTCs. sure sensor displays the specified value or more. In
this case, identify the cause by referring to Diagnostic
aid.

1 system check and
using a scan tool.
3 0.07 V (at idle)
Is the Common rail pressure sensor output volt- Go to Diagnostic

age the specified value or less? Go to Step 4. aid.
Check for installation condition of the common rail
pressure sensor, ECM and coupling connector.
4
required.


connector.
5 0V

age specified value? Go to Step 8. Go to Step 6.
circuit between ECM and common rail pres-
sure sensor using breaker box or DMM.
Codes.
Note:
Diagnostic Trouble Codes.
Open circuit
High resistance
required.

Codes.
Note:
Short circuit to common rail pressure sen-
sor ground circuit
required.

sensor).
Note:
service manual.


necessary.
10 Note:

Replace the ECM.
Note:

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

13 Go to each 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
Box.
3 2 1
TSWG0055
Name
1. GND
2. Signal
3. Power supply

sensor
Name
1. Breaker box
2. DMM
(V)
4.2
0 200(29008)
MPa(psi)
TSWG0201

6 Open circuit/ Resistance Disconnect the 87 Sensor connector 100 or less 10 M or
Key switch OFF
7 Short circuit to Resistance Disconnect the 82 101 10 M or 100 or less
ground circuit/ measurement sensor connector. 90 101 more
ground Key switch OFF 82 GND
90 GND
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)
EGR EGR EGR

5V
B+ B+ B+
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8

18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
0.5 0.5 0.5

L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80
2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113

V
W U
TSJJ0038

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
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 4.5V or more.
and ground in the common rail pressure sensor, which Action taken when DTC is set
shielded to avoid electrical noise etc. Trouble is displayed on the monitor of the
turer.)
Rail pressure feedback control stopped Wire disconnection inside harness cladding
causes.
EGR stopped
Actual rail pressure default setting (80 Mpa {11603 ECM connector
psi})
Recovery from failure Unmatched terminals are fitted.
and About recovery from failure in this section for Poor contact between terminal and wire
to history trouble and the key switch is turned Test description
Using the scan tool, or memory clear switch and 3. In case of present trouble, the Common rail pres-
diagnostic switch operation enables to clear DTCs. sure sensor displays the specified value or more. In
this case, identify the cause by referring to Diagnostic
Diagnostic aid aid.
If the intermittent trouble is suspected, the followings 5. If the Common rail pressure sensor displays the
may be the cause. specified value or less when terminals between the
common rail pressure sensor connector are shorted,
the circuit beyond the sensor is normal including ECM.

1 system check and
using a scan tool.
3 4.5V
Is the Common rail pressure sensor the specified Go to Diagnostic

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

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.
11 Note:

Replace the ECM.
Note:


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

14 Go to each DTC
15
required.

connector.
16 4.8V
pressure sensor power supply terminal and the
signal terminal.
Is the DMM indication the specified value or less? Go to Step 9. Go to Step 6.
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. GND
2. Signal
3. Power supply
Box.
Name
1. Breaker box
2. DMM

6 Short circuit to Voltage mea- Disconnect the 82 GND 0V 16 V or
power supply surement sensor connector. 90 GND more
Key switch OFF 90 Sensor connector
signal terminal
8 Open circuit/ Resistance Disconnect the 101 Sensor connec- 100 or less 10 M or
high resistance measurement sensor connector. tor ground terminal more
Key switch OFF
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.
TSWG0197
DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system
2 E-423 2 E-422 2 E-411 2 E-414

1 E-423 1 E-422 1 E-411 1 E-414
2 2 2 2 2 2
R P G W L Y
3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
116 E-56 120 E-56 E-56 121 E-56 E-56 117 E-56 Engine control
118 119
module (ECM)
Cylinder No. 3 Cylinder No. 2 Cylinder No. 1 Cylinder No. 4

B+ B+
TSJJ0035
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 Action taken when DTC is set
turer.)
6
1
Back-up mode
Injection for cylinder #1 stopped, EGR stopped
2
5 3
4

TSHK0032
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 block
6. Engine front Diagnostic aid
Fuel injection order is 1 3 4 2. may be the cause.
Main trouble symptom Defective harness routing
Intense engine vibration Worn harness cladding
Rough idling Wire disconnection inside harness cladding
Output lowering The following inspections are necessary to detect these
causes.
Preconditions when DTC is set ECM connector
Main relay power supply voltage is 18V or more. Poor connection of terminal from connector
70 rpm or more Unmatched terminals are fitted.
DTC P0611, P1261, or P0201 is not detected. Damage of connector lock
DTC set condition Damaged harness
Open/short circuit is detected in No. 1 cylinder Visually check the harness for damage.
injector drive circuit. Check the relevant items on the scan tool data
No. 1 cylinder injector monitor input signal does display while moving the connector and the har-
not exist for 2.5 seconds or more. ness which are related to the sensor. The varia-

1 system check and

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. Disconnect No. 1 cylinder injector connector.
3. Measure the resistance between the coupling 0.450.1
3 connector terminals (power supply terminal (20C {68F})
No. 1 cylinder injector drive signal terminal).
Is the resistance the specified value or less? Go to Step 4. Go to Step 6.

ECM and No. 1 cylinder injector connector
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

nector and coupling connector (H-12).
5 2. Remove the ECM.


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


necessary.
8 Note:

Replace the ECM.
Note:

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

11 Go to each DTC
Box.
Name
1. Breaker box
2. DMM

4 Open circuit/ Resistance Disconnect No. 1 119 No. 1 cylinder 100 or less 10 M or
high resistance measurement cylinder injector injector connector more
connector. drive signal terminal
Key switch OFF
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

2 E-423 2 E-422 2 E-411 2 E-414

1 E-423 1 E-422 1 E-411 1 E-414
2 2 2 2 2 2
R P G W L Y
3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
118 119
module (ECM)

B+ B+
TSJJ0035
turer.)
6
1
Back-up mode
2
5 3
4

TSHK0032
5. Cylinder block
causes.
DTC P0612, P1262 or P0202 is not detected. Damage of connector lock

1 system check and

Check the DTC.
seconds.
3. Check the DTC.
Go to Diagnostic

Note:
Codes.
Open circuit
High resistance



Note:
service manual.


necessary.
8 Note:

Replace the ECM.
Note:

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

11 Go to each DTC
Box.
Name
1. Breaker box
2. DMM

Key switch OFF
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

2 E-423 2 E-422 2 E-411 2 E-414

1 E-423 1 E-422 1 E-411 1 E-414
2 2 2 2 2 2
R P G W L Y
3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
118 119
module (ECM)

B+ B+
TSJJ0035
turer.)
6
1
Back-up mode
2
5 3
4

TSHK0032
5. Cylinder block
causes.

1 system check and

Check the DTC.
seconds.
3. Check the DTC.
Go to Diagnostic

Note:
Codes.
Open circuit
High resistance



Note:
service manual.


necessary.
8 Note:

Replace the ECM.
Note:

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

11 Go to each DTC
Box.
Name
1. Breaker box
2. DMM

Key switch OFF
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

2 E-423 2 E-422 2 E-411 2 E-414

1 E-423 1 E-422 1 E-411 1 E-414
2 2 2 2 2 2
R P G W L Y
3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
118 119
module (ECM)

B+ B+
TSJJ0035
turer.)
6
1
Back-up mode
2
5 3
4

TSHK0032
5. Cylinder block
causes.

1 system check and

Check the DTC.
seconds.
3. Check the DTC.
Go to Diagnostic

Note:
Codes.
Open circuit
High resistance



Note:
service manual.


necessary.
8 Note:

Replace the ECM.
Note:

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

11 Go to each DTC
Box.
Name
1. Breaker box
2. DMM

4 Open circuit/ Resistance Disconnect No. 4 117 No.4 cylinder 100 or less 10 M or
high resistance measurement cylinder injector injector connector ter- more
connector. minal
Key switch OFF
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 CKP sensor

signal sensor signal signal
5V 5V
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 108 E-56 107 E-56 109 E-56 95 E-56
EGR valve
EGR valve
18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 1 H-20 2 H-20 4 H-20
0.5 0.5 0.5

O/B T Y 0.75
B/W 0.75 B
0.5 0.5 0.5 0.5 0.5 0.5

L/W Br L W/B Gr/B V/W
2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113 2 E-98 1 E-98 3 E-98
CMP sensor (MRE) Common rail pressure sensor CKP sensor (MRE)
TSJJ0042
Description of circuit DTC set condition

The engine control module (ECM) detects the engine The engine speed exceeds setting value* for 0.5
speed based on the crankshaft position (CKP) sensor second or more (* depending on the machine man-
signal. The ECM stops the fuel injection to lower the ufacturer)
engine speed when the engine speed exceeds the
specified value. Action taken when DTC is set
Assuming the engine speed will not exceed the speci- is displayed depending on the machine manufac-
fied speed*. (* depending on the machine manufacturer.)
turer)
Back-up mode
Preconditions when DTC is set Limited injection amount 1
Key switch input voltage is 18V or more. Limitation is lifted if the speed decreases
Recovery from failure Diagnostic aid
Refer to 1E-297, List of Diagnostic Trouble Codes Load (fluid pressure pump etc.) is light.
and About recovery from failure in this section for Crankshaft position (CKP) sensor, camshaft posi-
recovery from failure. tion (CMP) sensor fault (signal fault etc.)
Engine body fault (supply pump, injector, body,
The conditions to clear the MIL/DTC etc.)
The present trouble turns to history trouble when ECM internal trouble
Check the connector for poor contact, the harness
for fault such as wear or bend, and the wire inside
The diagnosis lamp will go off after the code turns the harness for loosened wire causing short circuit
to history trouble and the key switch is turned to other circuits. Also, perform the function diagno-
OFF then ON again. sis to check the operation and control of each part.
Using the scan tool, or memory clear switch and Repair if faulty.
diagnostic switch operation enables to clear DTCs. When this DTC is detected, check the engine body
for trouble such as seizure and breakage.

system check, List
of Function
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 pressure sensor fault (low voltage fault, open circuit)
Engine control
Boost pressure module (ECM)
CKP sensor 5V
5V
Boost temperature
sensor signal
108 E-56 107 E-56 74 E-56 109 E-56 91 E-56 95 E-56
3 H-20 1 H-20 2 H-20 4 H-20 15 H-20 17 H-20 16 H-20 8 H-20
0.75 B
0.5 0.5 0.5

W/B Gr/B V/W 0.75 0.75 0.75 0.75 0.75
B/R R/L R/L L R/W
2 E-98 1 E-98 3 E-98 2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

CKP sensor (MRE)
TSJJ0037
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
5V 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
ECM through the boost pressure sensor signal circuit. 2.5 seconds or more.
The 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.
Action taken when DTC is set Defective harness routing
Trouble is displayed on the monitor of the Worn harness cladding
machine* or diagnosis lamp comes on. (* Nothing Wire disconnection inside harness cladding
is displayed depending on the machine manufac- The following inspections are necessary to detect these
turer.) causes.
Back-up mode ECM connector
Specified back-up value (depending on the Poor connection of terminal from connector
machine manufacturer) Unmatched terminals are fitted.
Boost pressure correction/EGR stopped Damage of connector lock
Damaged harness
and About recovery from failure in this section for Visually check the harness for damage.
recovery from failure. Check the relevant items on the scan tool data
The conditions to clear the MIL/DTC ness which are related to the sensor. The varia-
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 3. In case of present trouble, the MAP (manifold abso-
OFF then ON again. lute pressure) sensor displays the threshold value or
less. If more than the threshold value, identify the
Using the scan tool, or memory clear switch and cause by referring to Diagnostic aid.
diagnostic switch operation enables to clear DTCs. 5. If MAP (manifold absolute pressure) sensor dis-
plays the specified value or more when terminals
Diagnostic aid between the boost pressure sensor connector are
If the intermittent trouble is suspected, the followings shorted, the circuit beyond the sensor is normal includ-
may be the cause. ing ECM.

system check, List
of Function
2. Check the MAP (manifold absolute pressure)
3 sensor on the data display using a scan tool. 0.1V
Is the MAP (manifold absolute pressure) sensor Go to Diagnostic
the threshold value or less? 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 a jump cable. 4.8V
sensor on the data display using a scan tool.
Is the MAP (manifold absolute pressure) sensor

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

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

Replace the boost pressure sensor.
8

necessary.
10 Note:

Replace the ECM.
Note:

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

13 Go to each DTC
14
Check the value for boost pressure sensor using a
508 kPa (73.7
2. Start the engine. psi) or 254 kPa
15
3. Check the value for Boost pressure sensor (36.8 psi) (error
using a scan tool or monitor. value)
Does the display of Boost pressure sensor show Go to Diagnostic

pling connector.


circuit between ECM and boost pressure sen-
Note:
Trouble Codes.
Open circuit
High resistance

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

About boost pressure sensor The following illustration shows the correlation between
(V)
4.5
0.5
Name
1. Sensor ground 67(9.7) 333(48.3)
kPa(psi)
2. Sensor signal
TSHK0185
3 2 1 Refer to 1E-194, Example of use for breaker box,
Box.
TSJJ0140
Terminal Resistance
21 15 k
32 15 k
Characteristics of boost pressure sensor

The output voltage of boost pressure sensor changes
according to the boost pressure. The scan tool with
CAN communication displays a fixed value when the Name
value exceeds the threshold voltage. Therefore, judge 1. Breaker box
as it is more than the threshold value if the value of 67 2. DMM
kPa (9.7 psi) or 333 kPa (48.3 psi) is not changed.
When error occurs, error value (508 kPa {73.7 psi} or
254 kPa {36.8 psi}) is displayed.

Key switch OFF
Key switch OFF
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)
Engine control
CKP sensor 5V
5V
Boost temperature
sensor signal
108 E-56 107 E-56 74 E-56 109 E-56 91 E-56 95 E-56
3 H-20 1 H-20 2 H-20 4 H-20 15 H-20 17 H-20 16 H-20 8 H-20
0.75 B
0.5 0.5 0.5

W/B Gr/B V/W 0.75 0.75 0.75 0.75 0.75
B/R R/L R/L L R/W
2 E-98 1 E-98 3 E-98 2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

CKP sensor (MRE)
TSJJ0037
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 the boost pressure sensor signal circuit.
manifold, and the ECM detects the boost by this signal.
The boost pressure sensor includes following circuits. The ECM detects a low boost condition (the engine
load is low) when the signal voltage from the boost
5V power supply circuit pressure sensor is low, and a high boost condition (the
Ground circuit engine load is high) when the signal voltage from the
Boost pressure sensor signal circuit boost 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, the followings
DTC P1630 or P1634 is not detected. may be the cause.
DTC set condition Defective harness routing
Specified back-up value (depending on the Worn harness cladding
machine manufacturer) 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. (* Nothing ECM connector
is displayed depending on the machine manufac- Poor connection of terminal from connector
turer.)
Back-up mode Damage of connector lock
Specified back-up value (depending on the Poor contact between terminal and wire
machine manufacturer) Damaged harness
Boost pressure correction/EGR stopped Visually check the harness for damage.
Recovery from failure display while moving the connector and the har-
Refer to 1E-297, List of Diagnostic Trouble Codes ness which are related to the sensor. The varia-
and About recovery from failure in this section for tion of the display indicates the faulty part.
Test description
The conditions to clear the MIL/DTC Numbers below indicate step numbers in the chart.
The present trouble turns to history trouble when 3. In case of present trouble, the MAP (manifold abso-
the condition is out of the range from DTC set con- lute pressure) sensor displays the specified value or
dition (recovery from failure). more. If less than the specified value, identify the cause
by referring to Diagnostic aid.
The diagnosis lamp turns off when the trouble
5. If MAP (manifold absolute pressure) sensor dis-
code turns to the history trouble.
plays the specified value or less when the boost pres-
Using the scan tool, or memory clear switch and sure sensor connector is removed, the circuit beyond
diagnostic switch operation enables to clear history the sensor is normal including ECM.
trouble.

system check, List
of Function
3 sensor on the data display using a scan tool. 4.9V
Is the MAP (manifold absolute pressure) sensor Go to Diagnostic
the specified value or more? Go to Step 4. aid.
pling connector.


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

the specified value or less? 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:
(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.
10 Note:

Replace the ECM.
Note:

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

13 Go to each DTC
14
Check the value for boost pressure sensor using a
508 kPa (73.7
2. Start the engine. psi) or 254 kPa
15
3. Check the value for Boost pressure sensor (36.8 psi) (error
using a scan tool or monitor. value)
Does the display of Boost pressure sensor show 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 The following illustration shows the correlation between
(V)
4.5
0.5
Name
1. Sensor ground 67(9.7) 333(48.3)
kPa(psi)
2. Sensor signal
TSHK0185
3 2 1 Refer to 1E-194, Example of use for breaker box,
Box.
TSJJ0140
Terminal Resistance
21 15 k
32 15 k
Characteristics of boost pressure sensor

The output voltage of boost pressure sensor changes
according to the boost pressure. The scan tool with
CAN communication displays a fixed value when the Name
value exceeds the threshold voltage. Therefore, judge 1. Breaker box
as it is more than the threshold value if the value of 67 2. DMM
kPa (9.7 psi) or 333 kPa (48.3 psi) is not changed.
When error occurs, error value (508 kPa {73.7 psi} or
254 kPa {36.8 psi}) is displayed.

7, 18 Open circuit/ Resistance Disconnect the 109 Sensor connec- 100 or less 10 M or
Key switch OFF
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 5V
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 108 E-56 107 E-56 109 E-56 95 E-56
EGR valve
EGR valve
18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 1 H-20 2 H-20 4 H-20
0.5 0.5 0.5

O/B T Y 0.75
B/W 0.75 B
0.5 0.5 0.5 0.5 0.5 0.5

2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113 2 E-98 1 E-98 3 E-98
TSJJ0042

The crankshaft position (CKP) sensor detects the Cam pulse is normal.
engine speed. When the rotor fixed to the crankshaft DTC P0335, P0336, P0340, P0341 or P1345 is not
passes the tip of the CKP sensor, a voltage is gener- detected.
ated and turned into a pulse signal. The engine control
Engine under operation.
module (ECM) reads this pulse signal, and obtains the
engine speed and injection timing based on the signal.
DTC set condition
Main trouble symptom Cam signal exists but no crank signal.
Output lowering
White smoke emitted
Intense engine vibration possible
Engine stall possible (restart is possible when is displayed depending on the machine manufac-
camshaft position sensor is normal.) turer.)
Back-up mode
Control based on cam when cam sensor is normal
Recovery from failure Poor connection of terminal from connector
Refer to 1E-297, List of Diagnostic Trouble Codes Unmatched terminals are fitted.
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. Crank sensor fault
Using the scan tool, or memory clear switch and Important:
diagnostic switch operation enables to clear DTCs. For crank sensor fault, DTC wont be detected
unless the engine cranks for 14 revolutions. Espe-
Diagnostic aid cially when running with low speed such as idling,
If the intermittent trouble is suspected, the followings engine stalls before cranking for 14 revolutions if
may be the cause. no crank signal exist. In this case, the back-up
mode will not be active because DTC is not
detected. Therefore, the engine can be restarted
Defective harness routing even after it stalls, making it difficult to identify the
Worn harness cladding fault. If the engine experienced stall, raise the
Wire disconnection inside harness cladding engine speed up to No Load Max, and check if
The following inspections are necessary to detect these crank sensor fault is detected while cranking for 14
causes. revolutions. If crank sensor fault is detected at No
Load Max, DTC will be detected. If intermittent trou-
ble is found, raise the engine speed up to No Load
ECM connector
Max, and check if DTC is detected.

system check, List
of Function
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 the installation condition of the CKP sensor,
3
required.


1. Clear the DTC.
clear DTCs.

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

Remove the CKP sensor, and check the sensor tip
5 for scratch or damage.
Is the CKP sensor normal? Go to Step 6. Go to Step 10.
circuit between 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-
nal), List of Diagnostic Trouble Codes.
Open circuit
High resistance
required.

between ECM and CKP sensor using breaker
box or DMM.
Trouble Codes.
Note:
7 P0335 (Flash code 15) Crank sensor fault (no sig-
Open circuit
High resistance
Short circuit to power supply circuit or igni-
tion power supply circuit
required.


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

1. Check for the followings in the shield circuit
box or DMM.
Trouble Codes.
Note:
Open circuit
High resistance
required.

Replace the CKP sensor.
10
necessary.
12 Note:


Replace the ECM.
Note:

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

15 Go to each DTC
About CKP sensor
30
TSJJ0134
TSJJ0133
Name
1. Sensor signal
2. Sensor ground
About CKP sensor and CMP sensor signals Breaker box inspection procedure
Box.
1
TSJJ0127
Name
1. CKP signal
2. CMP signal
Name
1. Breaker box
2. DMM

Key switch OFF
ground measurement sensor connector. more
Key switch OFF
high resistance measurement sensor connector. tor signal terminal more
Key switch OFF
Key switch OFF

9 Open circuit/ Resistance Disconnect the 108 Sensor shield 100 or less 10 M or
high resistance measurement sensor connector. more
Key switch OFF
Short circuit to Resistance Disconnect the 108 95 10 M or 100 or less
CMP circuit measurement sensor connector. 108 107 more
Key switch OFF 108 109
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 5V
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 108 E-56 107 E-56 109 E-56 95 E-56
EGR valve
EGR valve
18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 1 H-20 2 H-20 4 H-20
0.5 0.5 0.5

O/B T Y 0.75
B/W 0.75 B
0.5 0.5 0.5 0.5 0.5 0.5

2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113 2 E-98 1 E-98 3 E-98
TSJJ0042

The crankshaft position (CKP) sensor detects the Cam pulse is normal.
engine speed. When the rotor fixed to the crankshaft DTC P0335, P0336, P0340, P0341 or P1345 is not
passes the tip of the CKP sensor, a voltage is gener- detected.
ated and turned into a pulse signal. The engine control
Engine under operation.
module (ECM) reads this pulse signal, and obtains the
engine speed and injection timing based on the signal.
DTC set condition
Main trouble symptom Number of pulse for crank signal is mismatched.
Output lowering
White smoke emitted
Intense engine vibration possible
Engine stall possible (restart is possible when is displayed depending on the machine manufac-
camshaft position sensor is normal.) turer.)
Back-up mode
Control based on cam when cam sensor is normal
Damaged harness
The diagnosis lamp will go off after the code turns tion of the display indicates the faulty part.
OFF then ON again. Crank sensor fault
Using the scan tool, or memory clear switch and Important:
diagnostic switch operation enables to clear DTCs. For crank sensor fault, DTC wont be detected
unless the engine cranks for 14 revolutions. Espe-
Diagnostic aid cially when running with low speed such as idling,
If the intermittent trouble is suspected, the followings engine stalls before cranking for 14 revolutions if
may be the cause. no crank signal exist. In this case, the back-up
mode will not be active because DTC is not
detected. Therefore, the engine can be restarted
Defective harness routing even after it stalls, making it difficult to identify the
Worn harness cladding fault. If the engine experienced stall, raise the
Wire disconnection inside harness cladding engine speed up to No Load Max, and check if
The following inspections are necessary to detect these crank sensor fault is detected while cranking for 14
causes. revolutions. If crank sensor fault is detected at No
Load Max, DTC will be detected. If intermittent trou-
ble is found, raise the engine speed up to No Load
ECM connector
Max, and check if DTC is detected.

system check, List
of Function
position (CKP) sensor.
2 2. Visually check the sensor for installation condi-
tion such as play or looseness.

Check the installation condition of the CKP sensor,
3
required.


1. Clear the DTC.
clear DTCs.

seconds.
4. Check the DTC.

Remove the CKP sensor, and check the sensor tip
Is the CKP sensor normal? Go to Step 6. Go to Step 8.
2. Remove the harness from the CKP sensor.
3. Connect the breaker box or DMM between the
CKP sensor terminals.
sensor fault (signal fault), List of Diagnostic
Trouble Codes.
6 0V
Note:
P0336 (Flash code 15) Crank sensor fault (signal
Is the DMM indication specified value? Go to Step 8. Go to Step 7.

1. Check the CKP sensor circuit for short circuit
to other signal circuit using breaker box or
DMM.
Trouble Codes.
7 Note:
P0336 (Flash code 15) Crank sensor fault (signal
required.

Replace the CKP sensor.
8
1. Visually check the sensor rotor for chipped
tooth.
9 2. If the trouble is detected, replace it.


necessary.
11 Note:

Replace the ECM.
Note:

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

14 Go to each DTC
About CKP sensor About CKP sensor and CMP sensor signals
TSJJ0133 TSJJ0127
Name Name
1. Sensor signal 1. CKP signal
2. Sensor ground 2. CMP signal

Box.
30
TSJJ0134
Name
1. Breaker box
2. DMM

6 Short circuit to Voltage mea- Disconnect the 109 GND 0V 1 V or more
power supply surement sensor connector.
other signal cir- surement sensor connector.
cuit Key switch ON
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 5V
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 108 E-56 107 E-56 109 E-56 95 E-56
EGR valve
EGR valve
18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 1 H-20 2 H-20 4 H-20
0.5 0.5 0.5

O/B T Y 0.75
B/W 0.75 B
0.5 0.5 0.5 0.5 0.5 0.5

2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113 2 E-98 1 E-98 3 E-98
TSJJ0042
Description of circuit Engine under operation.

The camshaft position (CMP) sensor detects the cam-
shaft rotation and identifies the cylinder. When the pul- DTC set condition
sar installed in the idle gear D sprocket passes the tip Crank signal exists but no cam signal.
of the camshaft position (CMP) sensor, a voltage is
generated and turned into a pulse signal. The engine Action taken when DTC is set
control module (ECM) reads this pulse signal, and Trouble is displayed on the monitor of the
identifies the cylinder based on the signal. machine* or diagnosis lamp comes on. (* Nothing
Engine does not start (restart).
Behavior does not change during engine running. Back-up mode
Engine running based on crank when it is normal
Preconditions when DTC is set After engine stops: Unable to identify cylinder
Key switch input voltage is 18V or more. (unable to restart)
Crank pulse is normal.
DTC P0335, P0336, P0340, P0341, P1345, or
P1635 is not detected.
Recovery from failure Defective harness routing
Refer to 1E-297, List of Diagnostic Trouble Codes Worn harness cladding
and About recovery from failure in this section for Wire disconnection inside harness cladding
recovery from failure. The following inspections are necessary to detect these
causes.
The conditions to clear the MIL/DTC Improper connection of harness connector and
The present trouble turns to history trouble when 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.
The diagnosis lamp will go off after the code turns Damage of connector lock
OFF then ON again. Poor contact between terminal and wire
Using the scan tool, or memory clear switch and Damaged harness
If the intermittent trouble is suspected, the followings ness which are related to the sensor. The varia-
may be the cause. tion of the display indicates the faulty part.
Improper connection of harness connector The cam gears are out of installation phase by one
tooth.

system check, List
of Function
Check for installation condition of the CMP sensor.
2. Visually check the sensor for installation condi-
2 tion such as play or looseness.

Check the 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
Is the CMP sensor normal? Go to Step 6. Go to Step 10.

circuit 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-
Open circuit
High resistance
required.

between ECM and CMP sensor using breaker
box or DMM.
Trouble Codes.
Note:
7 P0340 (Flash code 14) Cam sensor fault (no sig-
Open circuit
High resistance
required.

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


1. Check for the followings in the shield circuit
box or DMM.
Trouble Codes.
Note:
Open circuit
High resistance
required.

Replace the CMP sensor.
10
1. Visually check the camshaft gear for fault.
2. Check the alignment mark in the timing gear
11 and timing chain.
3. If the trouble is detected, repair or replace it.

necessary.
13 Note:

Replace the ECM.
Note:


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

16 Go to each DTC
About camshaft position (CMP) sensor
15
TSJJ0135
TSJJ0133
Name
Name 1. CMP sensor
1. Sensor signal
2. Sensor ground
Box.
1
TSJJ0127
Name
1. CKP signal
2. CMP signal
Name
1. Breaker box
2. DMM

Key switch OFF
ground measurement sensor connector. more
Key switch OFF
Key switch OFF
Short circuit to Voltage mea- Disconnect the 98 GND 5V 4 V or less /
power supply surement sensor connector. Voltage will 18 V or
circuit Key switch ON be pulled up more
when dis-
connecting
the connec-
tor. There-
fore, it
always will
be 5V.

Key switch OFF
Short circuit to Voltage mea- Disconnect the 101 GND 5V 4 V or less /
when dis-
connecting
the connec-
tor. There-
fore, it
always will
be 5V.
9 Open circuit/ Resistance Disconnect the 100 Sensor shield 100 or less 10 M or
high resistance measurement sensor connector. more
Key switch OFF
Short circuit to Resistance Disconnect the 100 87 10 M or 100 or less
CMP circuit measurement sensor connector. 100 98 more
Key switch OFF 100 101
On-board check procedure for sensors 3. Check the harness from coupling connector for
open circuit.
3 If both steps 1 and 2 are faulty, repair the har-
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

DTC: P0341 (Flash code 14) Cam sensor fault (signal fault)
Engine control
module (ECM)

5V 5V
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 108 E-56 107 E-56 109 E-56 95 E-56
EGR valve
EGR valve
18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 1 H-20 2 H-20 4 H-20
0.5 0.5 0.5

O/B T Y 0.75
B/W 0.75 B
0.5 0.5 0.5 0.5 0.5 0.5

2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113 2 E-98 1 E-98 3 E-98
TSJJ0042
Description of circuit Engine under operation.

The camshaft position (CMP) sensor detects the cam-
shaft rotation and identifies the cylinder. When the pul- DTC set condition
sar installed in the idle gear D sprocket passes the tip Number of pulse for cam signal is mismatched.
of the CMP sensor, a voltage is generated and turned
into a pulse signal. The engine control module (ECM) Action taken when DTC is set
reads this pulse signal, and identifies the cylinder Trouble is displayed on the monitor of the
based on the signal. machine* or diagnosis lamp comes on. (* Nothing
Engine does not start (restart).
Behavior does not change during engine running. Back-up mode
Engine running based on crank when it is normal
Preconditions when DTC is set After engine stops: Unable to identify cylinder
Key switch input voltage is 18V or more. (unable to restart)
Crank pulse is normal.
DTC P0335, P0336, P0340, P0341, P1345, or
P1635 is not detected.
Recovery from failure Improper connection of harness connector
Refer to 1E-297, List of Diagnostic Trouble Codes Defective harness routing
and About recovery from failure in this section for Worn harness cladding
recovery from failure. Wire disconnection inside harness cladding
The conditions to clear the MIL/DTC causes.
The present trouble turns to history trouble when Improper connection of harness connector and
the condition is out of the range from DTC set con- ECM connector
dition (recovery from failure). Poor connection of terminal from connector
The diagnosis lamp will go off after the code turns Unmatched terminals are fitted.
OFF then ON again. Damage of connector lock
Using the scan tool, or memory clear switch and Poor contact between terminal and wire
diagnostic switch operation enables to clear DTCs. Damaged harness

system check, List
of Function
Check for installation condition of the CMP sensor.
2. Visually check the sensor for installation condi-
2 tion such as play or looseness.

Check the 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
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 5V
Note:
P0341 (Flash code 14) Cam sensor fault (signal

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 and timing chain.
3. If the trouble is detected, repair or replace it.

necessary.
11 Note:


Replace the ECM.
Note:

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

14 Go to each DTC
About CMP sensor
15
TSJJ0135
TSJJ0133
Name
1. CMP sensor
Name
1. Sensor signal
2. Sensor ground
Box.
1
TSJJ0127
Name
1. CKP signal
2. CMP signal
Name
1. Breaker box
2. DMM

6 Short circuit to Voltage mea- Disconnect the 101 GND 5V 4 V or less /
when dis-
connecting
the connec-
tor. There-
fore, it
always will
be 5V.
7 Short circuit to Voltage mea- Disconnect the 98 GND 5V 4 V or less /
other signal cir- surement sensor connector. Voltage will 18 V or
cuit Key switch ON be pulled up more
when dis-
connecting
the connec-
tor. There-
fore, it
always will
be 5V.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
If a signal fault occurred at the cam sensor, in general,

DTC: P1345 will be detected.
Refer to 1E-613, DTC: P1345 (Flash code 16) Cam
sensor out of phase, List of Diagnostic Trouble Codes.
DTC: P0380 (Flash code 66) Glow relay circuit fault
Key switch
A A
OFF OFF
ON ON
START START
(ON) (ST) (ON) (ST)
(100A)*
(15A)*
(10A)*
Main relay
Starter
1 H-22
5
B/W
1 H-1
10 E-57 14 E-57 46 E-57
Engine control
module (ECM)
plug
TSJJ0032
Note: Preconditions when DTC is set

The QOS circuit is the same for both the starter ECM
Key switch input power supply voltage is 16 V or
control specifications and the safety relay specifica-
more and 32 V or less.
tions.
DTC P0380 is not detected.
DTC set condition
The glow relay cuts off the power supply voltage (24 V)
to the glow plug, and turns ON when the signal from No signal on the glow relay monitor at the glow
ECM is input. The ECM recognizes the starter switch relay drive instruction signal, or glow relay monitor
ON signal, and outputs the ON signal to the glow signal displayed at glow relay stop instruction.
relay.
Main trouble symptom Trouble is displayed on the monitor of the
Deterioration of starting function machine* or diagnosis lamp comes on. (* Nothing
turer.)
Back-up mode Wire disconnection inside harness cladding
No back-up action
causes.
ECM connector
The conditions to clear the MIL/DTC Poor contact between terminal and wire
the condition is out of the range from DTC set con- Visually check the harness for damage.
The diagnosis lamp turns off when the trouble display while moving the connector and the har-
code turns to the history trouble. ness which are related to the sensor. The varia-
Using the scan tool, or accelerator pedal operation tion of the display indicates the faulty part.
enables to clear history trouble.
Test description
Diagnostic aid
If the intermittent trouble is suspected, the followings 6. If the Glow relay displays ON when terminals
may be the cause. between the glow relay are shorted, the circuit beyond
Improper connection of harness connector the relay is normal including ECM.
Defective harness routing 9. If the Glow relay displays OFF when the glow
relay is removed, the circuit beyond the relay is normal
including ECM.

system check, List
of Function
1. Turn the key switch to ON position.
2. Check the Glow relay on the data display
3 using a scan tool.
Does the Glow relay display 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 the Glow relay on the data display
using a scan tool.
Go to Diagnostic
Does the Glow relay display 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
using a scan tool.
Does the Glow relay display ON? Go to Step 11. Go to Step 7.


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
8 Codes.
Open circuit
Short circuit to ground circuit
High resistance

2. Remove the glow relay.
9
using a scan tool.
Does the Glow relay display 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.
10 cedure, DTC: P0380 (Flash code 66) Glow
relay circuit fault, List of Diagnostic Trouble
Codes.

Replace the glow relay.
11
necessary.
13 Note:


Replace the ECM.
Note:

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

16 Go to each DTC
Check for installation condition of the glow relay,
ECM connector and coupling connector.


Box.
Name
1. Breaker box
2. DMM

8 Open circuit/ Resistance Disconnect the 10 FL 12 connector 10M or 10 M or
high resistance measurement relay. terminal No. 1 less more
Key switch OFF
Short circuit to Resistance Disconnect the 10 GND 10 M or 10M or
ground measurement relay. more less
Key switch OFF
10 Short circuit to Voltage mea- Disconnect the 10 GND 0V 16 V or
power supply surement relay. more
DTC: P0381 (Flash code 67) Glow plug lamp circuit fault
(15A)* Main relay
A A
diagnosis monitor
3 H-6
1 E-164
Machine
control unit
O/H
switch
CAN LOW CAN HIGH
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 102 E-56 8 E-57
Engine control
Tachometer signal
CAN HIGH CAN LOW
TSJJ0034

The QOS indicator lamp is installed in the meter. The No signal on the glow lamp monitor when the glow
engine control module (ECM) turns the QOS indicator lamp was instructed to come on, or a signal dis-
lamp on to tell the glow plug operation when the key played on the glow lamp monitor when the glow
switch is turned ON. The ECM detects the glow plug lamp was instructed to be turned off.
operating condition, and turns the lamp off upon com-
pletion of preheat. Action taken when DTC is set
Operation is not affected. is displayed depending on the machine manufac-
turer.)
Key switch input voltage is 16V or more. Back-up mode
DTC P0381 is not detected. 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
2. If the lamp does not come on with the key switch
If the intermittent trouble is suspected, the followings ON, open circuit, short circuit to the ground circuit,
may be the cause. blown light bulb, or ECM fault is suspected.
Blown lamp bulb 2. If the lamp does not go OFF, short circuit to the
Improper connection of harness connector ground circuit, meter circuit fault, or ECM fault is sus-
Defective harness routing pected.
4. If the lamp goes off when the ECM connector is
Worn harness cladding removed, the circuit beyond the ECM is normal includ-
Wire disconnection inside harness cladding ing meter.
The following inspections are necessary to detect these 7. If the lamp comes on when the lamp control terminal
causes. is shorted to the ground, the circuit beyond the ECM is
normal including meter.

1 system check and
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. Disconnect the connector from the ECM.
4 3. Turn the key switch to ON.
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 the installation condition of the meter and
ECM connector.



1. Check the circuit between QOS indicator lamp
and ECM for ground short circuit using breaker
box or DMM.
6
plug lamp circuit fault, List of Diagnostic Trou-
ble Codes.

3. Short between the QOS indicator lamp control
terminal of the ECM and the ground using
breaker box.
7 cedure, DTC: P0381 (Flash code 67) Glow
ble Codes.
5. Check if the QOS indicator lamp is ON.
ECM connector.


the fuse and the QOS indicator lamp.
Open circuit
High resistance

QOS indicator lamp and ECM using breaker
box or DMM.
10 ble Codes.
Open circuit
High resistance

Replace the meter.
11
Replace the QOS indicator lamp bulb.
12

necessary.
14 Note:

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.
Box.
Name
1. Breaker box
2. DMM
Step Item to be Checking Measuring condition Measuring terminal Normal value Abnormal
checked method No. value
6 Short circuit to Resistance Remove the meter 11 GND 10 M or 10M or less
ground measurement connector. more
Key switch OFF
7 Open circuit/ Lamp ON Remove the ECM. 11 Short circuit to Lamp ON Lamp OFF
high resistance Key switch ON the ground
10 Open circuit/ Resistance Remove the meter 11 Meter connector 10M or less 10 M or
high resistance measurement connector. QOS indicator lamp more
Key switch OFF terminal
DTC: P0487 (Flash code 44) EGR position sensor fault
Engine control
module (ECM)
EGR EGR EGR

5V
B+ B+ B+
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8

18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
0.5 0.5 0.5

L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80
2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113

V
W U
TSJJ0038
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
5V 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, the followings
W are all ON or all OFF approx. for 2.5 seconds or may be the cause.
more. Improper connection of harness connector
causes.
turer.)
Instruction to fully close EGR valve
Recovery from failure Damage of connector lock
Refer to 1E-297, List of Diagnostic Trouble Codes Poor contact between terminal and wire
and About recovery from failure in this section for Damaged harness
recovery from failure. Visually check the harness for damage.
The present trouble turns to history trouble when ness which are related to the sensor. The varia-
the condition is out of the range from DTC set con- tion of the display indicates the faulty part.
The diagnosis lamp will go off after the code turns Test description
to history trouble and the key switch is turned Numbers below indicate step numbers in the chart.
OFF then ON again. 3. Check all the signal circuits of the EGR position sen-
Using the scan tool, or memory clear switch and sors U, V, and W.

system check, List
of Function
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 80C (176F).
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.
8 Note:

Replace the ECM.
Note:

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

11 Go to each DTC
About EGR position sensor Breaker box inspection procedure
Box.
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 GND
94 GND
Open circuit/ Resistance Disconnect the 92 EGR valve con- 100 or less 10 M 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)
EGR EGR EGR

5V
B+ B+ B+
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8

18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
0.5 0.5 0.5

L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80
2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113

V
W U
TSJJ0038

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 or P0488 is not detected.
EGR motor drive circuit U
Main relay input power supply voltage is higher
EGR motor drive circuit V than 20 V but lower than 32 V.
EGR motor drive circuit W Difference between target EGR opening angle and
The ECM drives the EGR motor through the EGR actual one is 20% or less.
motor drive circuits U, V, and W. The ECM outputs
drive signals by the switching inside the ECM, and the DTC set condition
motor rotates with the combination of three-phase sig-
nals. Also, the valve opening angle is controlled by Difference between target valve lift and actual
duty. position is more than 20% approx. for 9.5 seconds
The ECM sets the DTC when the EGR motor drive duty or more.
is high and the difference between the target EGR posi-
tion and actual EGR position is large.
turer.)
Instruction to fully close EGR valve
causes.
Refer to 1E-297, 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.
Test description
5. Check all the EGR motor drive circuits U, V, and W.

system check, List
of Function
1. Perform EGR control test using a 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 the followings in the motor drive cir-
cuit 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.
9 Note:


Replace the ECM.
Note:

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

12 Go to each DTC
1. Remove the EGR valve.
2. Check the EGR valve for anchoring, clogging,
13 etc.

About EGR valve Breaker box inspection procedure
Box.
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
EGR valve check
TSJJ0138


5 Short circuit to Voltage mea- Disconnect the 111 GND 0V 16V or more
power supply surement EGR valve con- 103 GND
circuit nector. 110 GND
Key switch ON
ground measurement EGR valve con- 103 GND more
nector. 110 GND
Key switch OFF
Open circuit/ Resistance Disconnect the 111 EGR valve con- 100 or less 10 M 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
Engine coolant Vcc

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
0.75 0.75 0.75
B/Y L/Y W/B
Pulse 0.75 0.75 0.75 0.75

box 2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
Engine
coolant
temperature
pressure sensor
A
0.75
R
4 H-6 37 E-57 18 E-57

Vehicle
speed sensor
A
Meter
Machine
control
unit
coolant
temperature
gauge
Machine trouble
diagnosis monitor
TSJJ0036

The engine oil pressure sensor detects the engine oil Operation 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 approx for 3.5 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.
turer.)
Back-up mode The following inspections are necessary to detect these
causes.
Engine oil pressure default setting (120 kPa {17.4
psi}) Improper connection of harness connector and
ECM connector
Damaged harness
the condition is out of the range from DTC set con- Check the relevant items on the scan tool data
dition (recovery from failure). display while moving the connector and the har-
Test description
Diagnostic aid
If the intermittent trouble is suspected, the followings 3. In case of present trouble, the Engine oil pressure
may be the cause. sensor displays the specified value or more. In this
Improper connection of harness connector case, identify the cause by referring to Diagnostic aid.
Defective harness routing 5. If the Engine oil pressure sensor displays the spec-
Worn harness cladding ified value or more when the ECT sensor connector is
removed, the circuit beyond the sensor is normal
including ECM.

1 system check and
Check the value for engine oil pressure sensor
using a scan tool.
3 0.1V
3. Check the value for Engine oil pressure sen-
Is the Engine oil pressure sensor the specified 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 the specified


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.
9 Note:

Replace the ECM.
Note:


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

12 Go to each DTC
13
Check the value for engine oil pressure using a
2. Start the engine. 1016 kPa
14 (147.4 psi)
3. Check the value for Engine oil pressure using
(error value)
a scan tool or monitor.
Does the display of engine oil pressure show error Go to Diagnostic

15
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 Breaker box inspection procedure
Box.
1 2 3
TSWG0164
Name
1. Sensor ground
2. Sensor signal
Characteristics of engine oil pressure sensor

The output voltage of engine oil pressure sensor
changes according to the engine oil pressure. The scan Name
tool for CAN communication displays a fixed value 1. Breaker box
when the value exceeds the threshold voltage. There- 2. DMM
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 value1016 kPa (147.4 psi) is
displayed.
(V)
4.85
0.496
0 1088.5(157.9)
kPa(psi)
TSWG0202

ground Key switch OFF 80 79
80 GND
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P0523 (Flash code 294) Engine oil pressure sensor fault (high voltage fault, short to
power supply, ground short)

5V
Engine coolant Vcc

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
0.75 0.75 0.75
B/Y L/Y W/B
Pulse 0.75 0.75 0.75 0.75

box 2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
Engine
coolant
temperature
pressure sensor
A
0.75
R
4 H-6 37 E-57 18 E-57

Vehicle
speed sensor
A
Meter
Machine
control
unit
coolant
temperature
gauge
Machine trouble
diagnosis monitor
TSJJ0036

The engine oil pressure sensor detects the engine oil Operation 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 approx. for 3.5 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.
turer.)
Back-up mode The following inspections are necessary to detect these
causes.
Engine oil pressure default setting (120 kPa {17.4
psi}) Improper connection of harness connector and
ECM connector
Damaged harness
the condition is out of the range from DTC set con- Check the relevant items on the scan tool data
dition (recovery from failure). display while moving the connector and the har-
Test description
Diagnostic aid
If the intermittent trouble is suspected, the followings 3. In case of present trouble, the Engine oil pressure
may be the cause. sensor displays the specified value or more. In this
Improper connection of harness connector case, identify the cause by referring to Diagnostic aid.
Defective harness routing 5. If the Engine oil pressure sensor displays the spec-
Worn harness cladding ified value or less when terminals between the engine
oil pressure sensor connector are shorted, the circuit
beyond the sensor is normal including ECM.

1 system check and
Check the value for engine oil pressure sensor
using a scan tool.
3 4.85V
Is the Engine oil pressure sensor the specified 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 the specified

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.
11 Note:

Replace the ECM.
Note:


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

14 Go to each DTC
15
Check the value for engine oil pressure using a
2. Start the engine. 1016 kPa
16 (147.4 psi)
3. Check the value for Engine oil pressure using
(error value)
Does the display of Engine oil pressure show Go to Diagnostic

engine oil pressure sensor for short circuit to
Note:
17
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 Breaker box inspection procedure
Box.
1 2 3
TSWG0164
Name
1. Sensor ground
2. Sensor signal
Characteristics of engine oil pressure sensor

The output voltage of engine oil pressure sensor
changes according to the engine oil pressure. The scan Name
tool for CAN communication displays a fixed value 1. Breaker box
when the value exceeds the threshold voltage. There- 2. DMM
value of 0 kPa (0 psi) or 1088.5 kPa (157.9 psi) is not
changed.
When error occurs, error value1016 kPa (147.4 psi) is
displayed.
(V)
4.85
0.496
0 1088.5(157.9)
kPa(psi)
TSWG0202

6, 17 Short circuit to Voltage mea- Disconnect the 67 GND 0V 16V or more
Key switch OFF
Key switch OFF
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
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. (* Nothing diagnostic switch operation enables to clear DTCs.
turer.)

system check, List
of Function
1. Clear the DTC.
clear DTCs.

seconds.
set.
4. Check the DTC.
Is DTC P0601 detected? Go to Step 3.

necessary.
4 Note:


Replace the ECM.
Note:

6 Go to each DTC
DTC: P0603 (Flash code 54) EEPROM fault
The internal part of the ECM consists of ROM, No back-up action
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 is faulty. 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. (* Nothing Using the scan tool, or memory clear switch and
is displayed depending on the machine manufac- diagnostic switch operation enables to clear DTCs.
turer)

system check, List
of Function
1. Clear the DTC.
clear DTCs.
seconds.
3. Test run with the Preconditions when DTC is
set.
4. Check the DTC.

necessary.
4 Note:


Replace the ECM.
Note:

6 Go to each DTC
DTC: P0606 (Flash code 51) CPU fault
The internal part of the ECM consists of ROM, SUB-CPU stops CPU.
The ECM sets the DTC when the CPU fault or Sub-
CPU fault inside the ECM is detected.
Output lowering The conditions to clear the MIL/DTC
Unable to start The present trouble turns to history trouble when
DTC set condition dition (recovery from failure).
Sub-CPU detects main CPU fault in 100 msec The diagnosis lamp will go off after the code turns
after key switch ON. to history trouble and the key switch is turned
OFF then ON again.
Action taken when DTC is set Using the scan tool, or memory clear switch and
Trouble is displayed on the monitor of the diagnostic switch operation enables to clear DTCs.
turer.)

system check, List
of Function
1. Clear the DTC.
clear DTCs.

seconds.
set.
4. Check the DTC.

necessary.
4 Note:


Replace the ECM.
Note:

6 Go to each DTC
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. (* Nothing
storage, data clear and various controls. is displayed depending on the machine manufac-
The ECM sets the DTC when the CPU fault or Sub- turer)
CPU fault inside the ECM is detected.
Back-up mode
Main trouble symptom Limited injection amount 1
Output lowering
Preconditions when DTC is set Refer to 1E-297, List of Diagnostic Trouble Codes
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
OFF then ON again.

system check, List
of Function
1. Clear the DTC.
clear DTCs.

seconds.
set.
4. Check the DTC.

necessary.
4 Note:


Replace the ECM.
Note:

6 Go to each DTC
DTC: P0611 (Flash code 34) Charge circuit fault (bank 1)
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
81 E-57 4 E-57 3 E-57 1 E-57 43 E-57 62 E-57 52 E-57 38 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150 14 FL-150 6 FL-150
CAN CAN
LOW HIGH
DLC
5 FL-150 4 FL-150
CAN LOW CAN HIGH
TSJJ0033

The charge circuit inside the ECM is the voltage pres- When charge circuit bank 1 voltage inside ECU is
surizing circuit to apply voltage to the injector, and is low for 1.5 seconds or more.
divided in two systems. The charge circuit 1 supplies
the power supply voltage to the injectors of No. 1 cylin- Action taken when DTC is set
der and No. 4 cylinder. The ECM sets the DTC when
the voltage in the charge circuit 1 is excessively high or machine* or diagnosis lamp comes on. (* Nothing
excessively low. is displayed depending on the machine manufac-
turer.)
Intense engine vibration Back-up mode
Rough idling Common 1 stop (#1, #4 cylinders stopped), EGR
Output lowering stopped
Engine stall possible
Preconditions when DTC is set and About recovery from failure in this section for
Main relay power supply voltage is 18V or more.
The conditions to clear the MIL/DTC The diagnosis lamp will go off after the code turns
OFF then ON again.
dition (recovery from failure). Using the scan tool, or memory clear switch and

system check, List
of Function
Check the DTC.
3
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.
8 Note:


Replace the ECM.
Note:

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

11 Go to each 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
81 E-57 4 E-57 3 E-57 1 E-57 43 E-57 62 E-57 52 E-57 38 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150 14 FL-150 6 FL-150
CAN CAN
LOW HIGH
DLC
5 FL-150 4 FL-150
CAN LOW CAN HIGH
TSJJ0033

The charge circuit inside the ECM is the voltage pres- When ECU charge circuit bank 2 voltage is low for
surizing circuit to apply voltage to the injector, and is 1.5 seconds or more.
divided in two systems. The charge circuit 2 supplies
the power supply voltage to the injectors of No. 2 cylin- Action taken when DTC is set
der and No. 3 cylinder. The ECM sets the DTC when
the voltage in the charge circuit 2 is excessively high or machine* or diagnosis lamp comes on. (* Nothing
excessively low. is displayed depending on the machine manufac-
turer.)
Intense engine vibration Back-up mode
Rough idling Common 2 stop (#2, #3 cylinders stopped), EGR
Output lowering stopped
Engine stall possible
Preconditions when DTC is set and About recovery from failure in this section for
Main relay power supply voltage is 18V or more.
The conditions to clear the MIL/DTC The diagnosis lamp will go off after the code turns
OFF then ON again.
dition (recovery from failure). Using the scan tool, or memory clear switch and

system check, List
of Function
Check the DTC.
3
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.
8 Note:


Replace the ECM.
Note:

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

11 Go to each DTC
12 Is DTC P0612 detected? Go to Step 4. Go to Step 10.
DTC: P0615 (Flash code 19) Starter cut relay circuit fault
Key switch
A A
OFF OFF
ON ON
START START
(ON) (ST) (ON) (ST)
(100A)*
(15A)*
(10A)*
Main relay
Starter
1 H-22
5
B/W
1 H-1
10 E-57 14 E-57 46 E-57
Engine control
module (ECM)
plug
TSJJ0032

The starter cut switch is provided to prevent the starter The starter cannot be operated if it fails in open
from operating while the engine is running. The starter condition.
cut relay is the normal-close relay, and is located The starter cannot be driven if it fails in closed con-
between the main relay and the starter relay. When the dition.
key switch is turned to ON, the ECM sends the signal
to the starter cut relay to turn the relay OFF. When Preconditions when DTC is set
starting the engine, once the key switch is turned to
START position, the ECM stops the signal output to Key switch input power supply voltage is higher
the starter cut relay, and this enables the relay to turn than 16 V but lower than 32 V.
ON. After starting the engine, when the key switch DTC P0615 is not detected.
returns to ON position, the ECM sends the signal to
the starter cut relay again to turn the relay OFF. A DTC set condition
monitor circuit is provided inside the ECM to monitor No starter cut relay monitor signal on the starter
the relay operation. cut relay drive signal, or starter cut relay monitor
The ECM sets the DTC when the output to the starter signal is displayed when starter cut relay was sig-
cut relay does not match with the starter cut relay oper- naled to stop.
ation.
is displayed depending on the machine manufac- Fault in switch body
turer.)
Improper adjustment of switch
Back-up mode Improper connection of harness connector
No back-up action
Recovery from failure Wire disconnection inside harness cladding
causes.
recovery from failure. Improper connection of harness connector and
ECM connector
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 will go off after the code turns Damaged harness
OFF then ON again.
Test description
7. Measure using the breaker box.

system check, List
of Function
2. Remove the ECM connector, and install the
breaker box.
2 3. Connect the DMM between the starter cut 24V
relay drive terminal and the ground.

1. Connect the DMM between the starter cut
relay drive terminal and the ground.
3 2. Turn the key switch to START position, and 0V
crank the engine.
Go to Diagnostic
Is the DMM indication the specified value or less? aid. Go to Step 8.
Check for installation condition of the starter cut
relay, ECM connector and coupling connector.



3. Short between the terminals 2 4 in the
starter cut relay installing portion using jump
cable.
5 24V
relay drive terminal of the ECM and the
ground.
the fuse and the starter cut relay.
Open circuit
High resistance

starter cut relay and ECM using breaker box or
DMM.
cedure, DTC: P0615 (Flash code 19) Starter
cut relay circuit fault, List of Diagnostic Trouble
7 Codes.
Open circuit
High resistance

1. Turn the key switch to START position, and
crank the engine.
9 2. Check the Starter switch (ST) on the data
display using a scan tool.
Does the Starter switch (ST) display ON? Go to Step 11. Go to Step 10.
the ST terminal of the key switch and the ECM
cedure, DTC: P0615 (Flash code 19) Starter
10 Codes.
Open circuit
High resistance


11 relay drive terminal of the ECM and the 0V
ground.
1. Check the circuit between starter cut relay and
ECM for short circuit to the power supply cir-
breaker box or DMM.
12 cedure, DTC: P0615 (Flash code 19) Starter
Codes.

13
necessary.
15 Note:

Replace the ECM.
Note:

2. Clear the DTC.
17 clear DTCs.
4. Check the DTC.

18 Go to each DTC
Box.
Name
1. Breaker box
2. DMM

7 Short circuit to Resistance Disconnect the 14 GND 10 M or 100 or less
ground measurement relay. more
Key switch OFF
Open circuit/ Resistance Disconnect the 14 Relay installing 100 or less 10 M or
high resistance measurement relay. terminal more
Key switch OFF
10 Short circuit to Resistance Disconnect the key 46 GND 10 M or 100 or less
ground measurement switch connector. more
Key switch OFF
Open circuit/ Resistance Disconnect the key 46 Key switch 100 or less 10 M or
high resistance measurement switch connector. START terminal more
Key switch OFF
power supply surement relay.
DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault
(15A)* Main relay
A A
diagnosis monitor
3 H-6
1 E-164
Machine
control unit
O/H
switch
CAN LOW CAN HIGH
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 102 E-56 8 E-57
Engine control
Tachometer signal
CAN HIGH CAN LOW
TSJJ0034

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 for 1.5 seconds or
DTC detected. A monitor circuit is provided inside the more when it is instructed to come on, or diagnosis
ECM to monitor the lamp operation. lamp monitor signal displayed for 1.5 seconds or more
ECM sets the DTC when output to the diagnosis lamp when it is instructed to be turned off.
and its behaviour do not match.
Back-up mode
Main trouble symptom No back-up action
Operation is not affected.
dition (recovery from failure). Damaged harness
The diagnosis lamp will go off after the code turns Visually check the harness for damage.
OFF then ON again.

If the intermittent trouble is suspected, the followings Numbers below indicate step numbers in the chart.
may 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.
3. 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.
The 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.

1 system check and
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 3. Turn the key switch to ON.
4. Check if the diagnosis lamp is ON.
Does the diagnosis lamp go OFF? Go to Step 12. Go to Step 5.

ECM connector.


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-
6
sis lamp circuit fault, List of Diagnostic Trouble
Codes.


3. Short between the diagnosis lamp control ter-
minal of the ECM and the ground using
breaker box or DMM.
7 cedure, DTC: P0650 (Flash code 77) Diagno-
Codes.
5. Check if the diagnosis lamp is ON.
Does the diagnosis lamp come on? Go to Step 13. Go to Step 8.

ECM connector.


the fuse and the diagnosis lamp.
Open circuit
High resistance

diagnosis lamp and ECM using breaker box or
DMM.
cedure, DTC: P0650 (Flash code 77) Diagno-
10 Codes.
Open circuit
High resistance

Replace the meter.
11
Replace the diagnosis lamp bulb.
12

necessary.
14 Note:

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.
Box.
Name
1. Breaker box
2. DMM

6 Short circuit to Resistance Remove the meter 6 GND 10 M or 100 or less
ground measurement connector. more
Key switch OFF
7 Open circuit/ Lamp ON Remove the ECM. 6 Short circuit to the Lamp ON Lamp OFF
high resistance Key switch ON ground
10 Open circuit/ Resistance Remove the meter 6 Meter connector 100 or less 10 M or
high resistance measurement connector. diagnosis lamp termi- more
Key switch OFF nal
DTC: P1093 (Flash code 227) No pump pressure feed
3
1
4
5
TSJJ0103
Name
4. Pre-filter
Engine control
module (ECM)
EGR EGR EGR

5V
B+ B+ B+
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8

18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
0.5 0.5 0.5

L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80
2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113

V
W U
TSJJ0038
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 puressure

4
3 :Actual rail presure
Absolute pressure
5
50MPa(7252psi)
Actual 1 P1093
2
t2 > 5sec
t1 > 3sec
15MPa Actual 2
(2176psi) P0087
TSJJ0111
1
TSJJ0137
Name
1. Fuel pump strainer Trouble is displayed on the monitor of the
2. Pre-fuel filter machine* or diagnosis lamp comes on. (* Nothing
3. Electromagnetic pump filter is displayed depending on the machine manufac-
4. Main fuel filter turer.)
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-297, List of Diagnostic Trouble Codes
DTC P0090, P0192, P0193, P0201, P0202, and About recovery from failure in this section for
P0203, P0204, P0611, P0612, P1093, P1095, recovery from failure.
P1261, P1262 or P1635 is not detected.
Duty to SCV is 33% or less, or pressure feed is
28000 mm3/sec (1.7 cuin/sec) or more. The present trouble turns to history trouble when
1200 rpm or more the condition is out of the range from DTC set con-
DTC set condition The diagnosis lamp will go off after the code turns
Actual rail pressure is 50 MPa (7252 psi) or more lower
OFF then ON again.
than target rail pressure for 5 seconds or more.
Diagnostic aid
Followings are suspected as the cause.
Injector internal trouble
Improper operation due to foreign matter etc. in the
SCV which is installed in the supply pump.
Fuel system pipe fault (fuel leakage, clogging,
crush, etc.)
Fuel filter fault (clogging)
Fuel tank fault (clogging)
Pressure limiter trouble (operation under specified 8. If the Common rail pressure sensor displays the
pressure, degradation of sealability) specified value or more when the common rail pressure
ECM trouble sensor connector is removed, the circuit beyond the
10, 23. If rise of fuel level or diesel fuel odor was found,
fuel leakage in the injector portion may be the cause of
Test description
the DTC detection.

system check, List
of Function
2 fuel tank for freeze or waxing. (at cold temper-
ature)

3
5 4351 psi) 0
Important:
6 Refer to 1E-534, Fuel discharge inspection
procedure, DTC: P1093 (Flash code 227) No
pump pressure feed, List of Diagnostic Trouble
Codes.

2. Check the Common rail pressure on the data
display using a scan tool. At engine
3. Start the engine and run it at idle. stopped: Differ-
ential pressure
the data display using a scan tool. 30 MPa (
7
4351 psi); At
5. Race it quickly for about 5 times. idling, racing:
6. Check the Differential fuel rail pressure on 5 MPa (725
the data display using a scan tool. psi)


connector.
8 4.8V

box or DMM.
9 cedure, DTC: P1093 (Flash code 227) No
Codes.

10 light oil odor.
firmed.
11 Note:
service manual.

Check the injector.
1. Clear the DTC.
clear DTCs.
3. Select the Actuator test from the menu.
12

Note:
service manual.


necessary.
15 Note:
Is the rewriting completed? Go to Step 18. Go to Step 16.

Replace the ECM.
Note:

17 sensor).
2. Clear the DTC.
clear DTCs.
seconds.
set.
5. Check the DTC.

19 Go to each DTC
Important:
20 Refer to 1E-534, Fuel discharge inspection
procedure, DTC: P1093 (Flash code 227) No
Codes.


connector.
21 4.8V
4. Measure the voltage between the common rail
pressure sensor connector power supply ter-
minal and the ground.
box or DMM.
22 cedure, DTC: P1093 (Flash code 227) No
Codes.

23 light oil odor.
firmed.
24 Note:
service manual.


About common rail pressure sensor Fuel discharge inspection procedure
side in the following procedure.
pump.
mixed in fuel.
3 2 1
5
4
3
TSWG0055
Name
1. Sensor ground
2. Sensor signal

sensor 1
TSHK0164
(V)
4.2 Name
1. Supply pump
2. Fuel tank
3. Pre-fuel filter
5. Fuel filter
0 200(29008)
MPa(psi)
TSWG0201
ply pump.
Note:
5
3
procedure.
6
5
4
1
3 2
TSHK0167
Name
1. Supply pump
2. Fuel tank
3. Pre-fuel filter
5. Fuel filter
2
TSHK0165
Name
1. Supply pump
2. Fuel tank
3. Pre-fuel filter
5. Fuel filter
6. Clear pipe
in the fuel hose.
It is normal if pulsation exists. 2

and check again from Step 1. 1
replace the pump.
TSHK0107
Name
1. Fuel inlet port
2. Fuel outlet port
1
2
Step 1.

3
TSHK0106 Refer to 1E-194, Example of use for breaker box,
Name Breaker box inspection procedure, How to Use Breaker
1. Electromagnetic pump Box.
2. + terminal
3. - terminal

with your mouth.
inate sticking.
Name
1. Breaker box
2. DMM

9, 22 Short circuit to Voltage mea- Disconnect the 82 GND 0V 1 V or more
cuit Key switch ON
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1095 (Flash code 225) Pressure limiter open
3
1
4
5
TSJJ0103
Name
4. Pre-filter
Engine control
module (ECM)
CMP sensor Common rail pressure

5V
2 E-161
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56
SCV
EGR valve
EGR valve
1 E-161
0.75 0.75
R/B R/W
1 H-6 2 H-6
18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
O/B T Y 0.75
B/W
0.5 0.5 0.5

L/W Br L
2 E-112 1 E-112 3 E-112 97 E-56 89 E-56 105 E-56 113 E-56

1 E-113 2 E-113 3 E-113
B+
CMP sensor (MRE) Common rail pressure sensor Engine control

module(ECM)
TSJJ0141
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
Fuel system filter
Common rail
3
pressure
T>1sec=P1095
200 MPa
(29008psi)
5
190 MPa T
(27557psi)
185 MPa
(26832psi)
2
T
T>5sec=P0088
TSHK0043
1
TSJJ0137
Name
1. Fuel pump strainer Trouble is displayed on the monitor of the
2. Pre-fuel filter machine* or diagnosis lamp comes on. (* Nothing
3. Electromagnetic pump filter is displayed depending on the machine manufac-
4. Main fuel filter turer.)
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 not Refer to 1E-297, List of Diagnostic Trouble Codes
detected. and About recovery from failure in this section for
50rpm 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
Overshoot caused by improper operation of SCV
installed to the supply pump.
If the engine starts with the signal (voltage) is not Fuel system pipe fault (clogging etc.)
sent to the SCV, common rail pressure reaches Fuel filter fault (temporary clogging due to waxing
200MPa (29008psi) due to the normal open struc- at low temperatures, improper tightening of filter
ture of the SCV. Common rail pressure becomes cartridge, etc.)
high pressure status (for approx. 2 sec. at crank-
Fuel tank fault (temporary clogging, air mixed due
ing) and the pressure limiter opens, then common
to fuel shortage, air mixed due to modified fuel
rail pressure decreases to 50MPa (7252psi). Out-
pipe for additional tank etc.)
put is lowering since common rail pressure is lim-
ited. Pressure limiter trouble (operation under specified
pressure, degradation of sealability)
ECM trouble
Running out of fuel
200MPa
(29008psi)
Test description
50MPa
(7252psi)
t1 = 2sec t
TSHK0170

system check, List
of Function
Check the SCV connector.
1. Make sure that the connector is not in the fol-
lowing condition.
Connector disconnection
2 Looseness or breakage of connector
Poor contact in wiring
2. If the trouble is detected, repair it.


1. Check and record the DTC.
2. Clear the DTC.
clear DTCs.
3. Check the fuel amount, and add fuel as
required.
Important:
If fuel is low, P1095 may be detected due to
entry of air.
3 Important:
If air bleeding is insufficient, overshoot
exceeds 200 MPa (29008 psi) and DTC will
be detected.
Bleeding air from fuel must be performed
correctly, following the procedure.
Refer to 1E-201, Bleed air from fuel sys-
tem, Description of function and operation
for engine control (common rail) system,
Engine Control System for work procedure.
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 4. 5.
Narrow down the cause.
1. Clear the DTC.
clear DTCs.
2. Perform the test drive.
Important:
4
Connect another pipe to the supply pump inlet
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.

Check the clogging in the following procedure.
Fuel filter (main fuel filter, pre-fuel filter,
gauze filter)
5 Fuel tank (pump strainer)
Fuel system pipe
fuel tank for freeze or waxing. (at cold temper-
ature)


6
3. Start the engine and run it at idle. At engine
stopped: 30
MPa (4351
8 the data display using a scan tool.
psi); At idling,
5. Race it quickly for about 5 times. racing: 5 MPa
6. Check the Differential fuel rail pressure on (725 psi)

next step.

scan tool.
next step.

be replaced. Remember this.
One or items from steps 9 11 detected? Go to Step 12. Go to Step 13.

Replace the SCV.
Note:
ment procedure.

connector.
13 0V
Is the Common rail pressure sensor specified


Note:
Bleed air completely after the parts are
replaced. If the air was not bled sufficiently,
14 P1095 may be detected due to overshoot of
fuel pressure.
For work procedure, refer to Engine section in
the service manual.

box or DMM.
cedure, DTC: P1095 (Flash code 225) Pres-
sure limiter open, List of Diagnostic Trouble
Codes.
15
Note:
P1095 (Flash code 225) Pressure limiter open, List

necessary.
17 Note:

Replace the ECM.
Note:

sensor).
Note:
service manual.


1. Restore the machine.
3. Clear the DTC.
20 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.
21 Refer to 1E-21, How to clear DTC, Procedure
clear DTCs.
set.
5. Check the DTC.

1. Clear the DTC.
clear DTCs.
If Tech2 is not available, Go to Step 26.
3. Select the Actuator test from the menu. 5 MPa (725
22
4. Select the Rail pressure control in the Com- psi)
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-

next step.

scan tool.
next step.



Replace the SCV.
Note:
ment procedure.

Important:
Bleed air completely after the parts are
replaced. If the air was not bled sufficiently,
27 P1095 may be detected due to overshoot of
fuel pressure.
For work procedure, refer to Engine sec-
tion in the service manual.

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

29 Go to each DTC
connector.
pressure sensor connector signal terminal and
30 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.

About common rail pressure sensor Breaker box inspection procedure
Box.
3 2 1
TSWG0055
Name
1. Sensor ground
2. Sensor signal

sensor
Name
1. Breaker box
2. DMM
(V)
4.2
0 200(29008)
MPa(psi)
TSWG0201

cuit Key switch ON
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground
short)
Engine control
CKP sensor 5V
5V
Boost temperature
sensor signal
108 E-56 107 E-56 74 E-56 109 E-56 91 E-56 95 E-56
3 H-20 1 H-20 2 H-20 4 H-20 15 H-20 17 H-20 16 H-20 8 H-20
0.75 B
0.5 0.5 0.5

W/B Gr/B V/W 0.75 0.75 0.75 0.75 0.75
B/R R/L R/L L R/W
2 E-98 1 E-98 3 E-98 2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

CKP sensor (MRE)
TSJJ0037

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 approx. for 3.5 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. (* Nothing
low; if the resistance is high (temperature is low), the is displayed depending on the machine manufac-
voltage becomes high. turer.)

Operation is not affected. Boost temperature default setting (30C {86F})
causes.
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
may be the cause.
3. In case of present trouble, the Boost temperature
Improper connection of harness connector sensor displays the specified value or less. If more
Defective harness routing than the specified value, identify the cause by referring
Worn harness cladding to Diagnostic aid.
Wire disconnection inside harness cladding 5. If the Boost temperature sensor displays the speci-
fied value or more when terminals between the boost
temperature sensor connector are shorted, the circuit
beyond the sensor is normal including ECM.

system check, List
of Function
2. Check the Boost temperature sensor on the
3 data display using a scan tool. 0.1V
Is the Boost temperature sensor the specified 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 the Boost temperature on the data
Is the Boost temperature the specified value or

more? Go to Step 8. Go to Step 6.

circuit between ECM and boost temperature
sensor, using breaker box or DMM.
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

between ECM and boost temperature sensor,
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.
10 Note:


Replace the ECM.
Note:

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

13 Go to each DTC
14
Check the value for boost temperature using a
15
3. Check the value for Boost temperature using (error value)
Does the display of Boost temperature show error Go to Diagnostic

pling connector.


circuit between ECM and boost temperature
sensor, using breaker box or DMM.
Codes.
Note:
Open circuit
High resistance

Codes.
Note:
18 P1112 (Flash code 295) Boost temperature sensor
Short circuit to boost temperature sensor
ground circuit
Open circuit
High resistance

About boost temperature sensor Characteristics of boost temperature sensor
The output voltage of boost temperature sensor
changes according to the boost temperature. The scan
tool for CAN communication displays a fixed value
when the value exceeds the threshold voltage. There-
value of 40C (40F) or 120C (248F) is not
changed.
played.
(V)
4.9824
Name
1. Signal
2. GND
1.1719
-40 120
(-40) (248) F
TSWG0204
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
Box.
Name
1. Breaker box
2. DMM

Key switch OFF
Key switch OFF
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.
TSWG0197
DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open
circuit, short to power supply circuit)
Engine control
CKP sensor 5V
5V
Boost temperature
sensor signal
108 E-56 107 E-56 74 E-56 109 E-56 91 E-56 95 E-56
3 H-20 1 H-20 2 H-20 4 H-20 15 H-20 17 H-20 16 H-20 8 H-20
0.75 B
0.5 0.5 0.5

W/B Gr/B V/W 0.75 0.75 0.75 0.75 0.75
B/R R/L R/L L R/W
2 E-98 1 E-98 3 E-98 2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

CKP sensor (MRE)
TSJJ0037

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 50C (122F) or more, or 5
manifold.
minutes or more has elapsed after starting engine.
The resistance is low when the intake air temperature
is high, and is high when the temperature is low. The
DTC set condition
ECM energizes 5 V to the boost temperature sensor
through the pull up resistance, and calculates the boost Boost temperature sensor voltage is 4.95V or less
temperature from the change in voltage, to utilize vari- approx. for 3.5 seconds or more.
ous control such as fuel injection control. If the resis-
tance is low (temperature is high), the voltage becomes Action taken when DTC is set
low; if the resistance is high (temperature is low), the Trouble is displayed on the monitor of the
voltage becomes high. machine* or diagnosis lamp comes on. (* Nothing
Operation is not affected.
Boost temperature default setting (30C {86F}) Wire disconnection inside harness cladding
Recovery from failure causes.
Refer to 1E-297, 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 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
The diagnosis lamp turns off when the trouble
code turns to the history trouble. Check the relevant items on the scan tool data
If the intermittent trouble is suspected, the followings Numbers below indicate step numbers in the chart.
may be the cause. 3. In case of present trouble, the Boost temperature
Improper connection of harness connector sensor displays the specified value or more. If less
Defective harness routing than the specified value, identify the cause by referring
to Diagnostic aid.

system check, List
of Function
2. Check the Boost temperature sensor on the
3 data display using a scan tool. 4.94V
Is the Boost temperature sensor the specified 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.
9 Note:


Replace the ECM.
Note:

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

12 Go to each DTC
13
Check the value for boost temperature using a
14
3. Check the value for Boost temperature using (error value)
Does the display of Boost temperature show error 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 Characteristics of boost temperature sensor
The output voltage of boost temperature sensor
changes according to the boost temperature. The scan
tool for CAN communication displays a fixed value
when the value exceeds the threshold voltage. There-
value of 40C (40F) or 120C (248F) is not
changed.
played.
(V)
4.9824
Name
1. Signal
2. GND
1.1719
-40 120
(-40) (248) F
TSWG0204
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
Box.
Name
1. Breaker box
2. DMM

6, 17 Open circuit/ Resistance Disconnect the 109 Sensor connec- 100 or less 10 M or
Key switch OFF
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: P1173 (Flash code 542) Overheat

5V
Engine coolant Vcc

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
0.75 0.75 0.75
B/Y L/Y W/B
Pulse 0.75 0.75 0.75 0.75

box 2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
Engine
coolant
temperature
pressure sensor
A
0.75
R
4 H-6 37 E-57 18 E-57

Vehicle
speed sensor
A
Meter
Machine
control
unit
coolant
temperature
gauge
Machine trouble
diagnosis monitor
TSJJ0036
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%
100 (212 )
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 Warning (248 )
coolant temperature exceed certain level based on the indication
signal from the ECT sensor. DTC set

Output lowering (221 )
110
(230 )
Fuel flow is regulated during overheat when the Engine coolant temperature
temperature exceeds 100C (212F). TSHK177

Preconditions when DTC is set Diagnostic aid
Key switch input voltage is 18V or more. If the intermittent trouble is suspected, the followings
DTC P1630, P1633, P0117 or P0118 is not may be the cause.
detected. Improper connection of harness connector
Engine under operation Defective harness routing
DTC set condition Wire disconnection inside harness cladding
Engine coolant temperature is more than 110C The following inspections are necessary to detect these
(230F) for 5 seconds and more causes.
Action taken when DTC is set ECM connector
The diagnosis lamp does not come on. Poor connection of terminal from connector
Back-up mode
No back-up action Poor contact between terminal and wire
Damaged harness
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.
The present trouble turns to history trouble when Test description

dition (recovery from failure). Numbers below indicate step numbers in the chart.
the specified value or less when the ECT sensor con-
nector is removed, the sensor is faulty.
OFF then ON again.
9. If no DTC is detected, intermittent trouble is sus-
Using the scan tool, or memory clear switch and pected. Identify the cause by referring to Diagnostic
diagnostic switch operation enables to clear DTCs. aid.

system check, List
of Function
2 2. Check the DTC.
Go to the relevant
Is DTC P0088, or P1093 detected? DTC detected. Go to Step 3.
4.9V/40C (
4 4. Check the Engine coolant temperature sen-
40F)
sor on the data display using a scan tool.

specified value or more? Go to Step 6. Go to Step 5.

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-
tic Trouble Codes.

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 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.
11 Note:

Replace the ECM.
Note:

13 Go to each DTC
14 4. Check the display of the Engine coolant tem- 40C (40F)
perature.
Is the Engine coolant temperature the specified

About ECT sensor Breaker box inspection procedure
2 1 step. After inspection, return to the diagnostic step.
Box.
1 2 3
TSWG0061
Name
1. Sensor ground (for engine control)
2. Sensor signal (for engine control)
3. Sensor signal (for meter)
Characteristics of ECT sensor

The output voltage of ECT sensor changes according
to the engine coolant temperature. The scan tool for Name
CAN communication displays a fixed value when the 1. Breaker box
value exceeds the threshold voltage. Therefore, judge 2. DMM
(V)
4.7441
0.2129
-40 120
(-40) (248) F
TSWG0181

other signal cir- surement sensor connector.
cuit Key switch ON
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault
Key switch(ON)
(15A)*
Idling Regulation
Idle up Idle down Mode map Mode map Mode map Road advance
selector mode
switch switch switch 0 switch 1 switch 2 switch
switch switch
29 E-57 30 E-57 31 E-57 49 E-57 50 E-57 51 E-57 33 E-57 45 E-57
Engine control
module (ECM)
Idling selector Idle up Idle down Mode map Mode map Mode map Regulation mode Road advance
switch signal switch signal switch signal switch 0 signal switch 1 signal switch 2 signal switch signal switch signal
TSJJ0040

The idling control switch is provided to adjust idle Key switch input voltage is 18V or more.
speed during warming-up, and is available for use
when the idling control selector switch is in Manual. DTC set condition
The power supply voltage is supplied to the idling con-
When both of idling control up signal and idling
trol switch through the key switch. By pressing the Up control down signal are ON.
or Down, each ground circuit is completed and the
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 Trouble is displayed on the monitor of the
side at the same time. machine* or diagnosis lamp comes on. (* Nothing
Idling goes down due to the Idle-down switch being pri-
Back-up mode
oritized.
No backup action
causes.
Damaged harness
If the intermittent trouble is suspected, the followings tion of the display indicates the faulty part.
may be the cause.
Fault in switch body Test description
Improper adjustment of switch Numbers below indicate step numbers in the chart.
Improper connection of harness connector 3. If the Idle up switch and Idle down switch display
Defective harness routing OFF when the idling control switch connector is
Worn harness cladding removed, the circuit is shorted between idle up circuit
and idle down circuit, or the switch is faulty.

system check, List
of Function
2. Disconnect the idling control switch connector.
3 4. Check the Idle up switch and Idle down
switch on the data display using a 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
4 cedure, DTC: P1225 (Flash code 31) Idle UP/
DOWN switch fault, List of Diagnostic Trouble
Codes.

1. Check the idle down-side circuit between idling
control switch and ECM for short circuit to the
5 cedure, DTC: P1225 (Flash code 31) Idle UP/
DOWN switch fault, List of Diagnostic Trouble
Codes.


Replace the idling control switch.
6
necessary.
8 Note:

Replace the ECM.
Note:

2. Clear the DTC.
10 clear DTCs.
4. Check the DTC.

11 Go to each DTC
About idling control switch
Note:
Refer to the machines manual for installing position of
the idling control switch.

Box.
Name
1. Breaker box
2. DMM

power supply surement switch connector.
power supply surement switch connector.
DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault
2 E-423 2 E-422 2 E-411 2 E-414

1 E-423 1 E-422 1 E-411 1 E-414
2 2 2 2 2 2
R P G W L Y
3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
118 119
module (ECM)

B+ B+
TSJJ0035

The COMMON circuit is providing the power supply Main relay power supply voltage is 18V or more.
voltage pressurized in the charge circuit inside the 70 rpm or more
ECM to the injector, and is divided in two systems. The
None of the following DTC sets are detected; DTC
COMMON circuit 1 provides the power supply voltage
P0611 and P1261, P0201 orP0204.
to No.1 and 4 cylinder injector. The ECM sets the DTC
when faults are detected simultaneously for all the
DTC set condition
injector drive circuits of COMMON 1 system.
None of injector monitor input signal for COMMON
Main trouble symptom 1 system exists approx. for 2.5 seconds or more.
Rough idling
Output lowering
Engine blow up fault is displayed depending on the machine manufac-
Engine stall possible turer.)
Back-up mode Diagnostic aid
Common 1 stop (#1, #4 cylinders stopped), EGR If the intermittent trouble is suspected, the followings
stopped may be the cause.
causes.
to history trouble and the key switch is turned Damage of connector lock

system check, List
of Function
2. Remove the ECM-side harness connector
from the coupling connector (H-12).
3. Connect the DMM between the injector power
2 supply 1 circuit and the ground. 7.0V
H1 Female-side No. 4

3. Disconnect No. 1 and 4 cylinder injector con-
nectors.
3 1.0
4. Measure the resistance between the coupling
connector (H-12) and the injector connector.
H12 Male-side No.4 and E411 No.2

nector and coupling connector (H12).



1. Check for the followings in the injector power
supply 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

6 3. Measure the resistance between the No. 1 cyl- 10M
inder injector drive circuit and the ground.
H12 Male-side No.8
Is the resistance the specified value or more? Go to Step 7. Go to Step 8.

H12 Male-side No.5

1. Check the No. 1 cylinder injector drive circuit
between ECM and coupling connector (H-12)
for ground short circuit using breaker box or
DMM.
8 Note:
P1261 (Flash code 158) Injection nozzle common 1
Codes.


DMM.
9 Note:
Codes.

1. Check for installation condition of the injector
connector.

1. Remove the injector connector from the injec-
tor.
No. 1 cylinder, No. 4 cylinder
11 2. Measure the resistance between each injector 10M
terminal and the ground.
or DMM.
12
Note:
Codes.


ignition power supply circuit, using breaker box
or DMM.
13
Note:
Codes.

Replace the engine harness.
14
Replace the injector.
Note:
service manual.

necessary.
17 Note:

Replace the ECM.
Note:


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

20 Go to each DTC

Box.
Name
1. Breaker box
2. DMM

5 Open circuit/ Resistance Remove the ECM- 121 Female-side ter- 100 or less 10 M or
high resistance measurement side harness con- minal more
nector from the (H12 No.4)
coupling connec-
tor.
Key switch OFF
Short circuit to Resistance Remove the ECM- 121 GND 10 M or 100 or less
ground measurement side harness con- more
nector from the
coupling connec-
tor.
Key switch OFF

8 Short circuit to Resistance Remove the ECM- 119 GND 10 M or 100 or less
nector from the
coupling connec-
tor.
Key switch OFF
nector from the
coupling connec-
tor.
Key switch OFF
12 Short circuit to Voltage mea- Remove the ECM- 119 GND 0V 16V or more
power supply surement side harness con-
circuit nector from the
coupling connec-
tor.
Key switch OFF
coupling connec-
tor.
Key switch OFF
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault
2 E-423 2 E-422 2 E-411 2 E-414

1 E-423 1 E-422 1 E-411 1 E-414
2 2 2 2 2 2
R P G W L Y
3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12
118 119
module (ECM)

B+ B+
TSJJ0035

The COMMON circuit is providing the power supply Main relay power supply voltage is 18V or more.
voltage pressurized in the charge circuit inside the 70 rpm or more
ECM to the injector, and is divided in two systems. The
None of the following DTC sets are detected; DTC
COMMON circuit 2 provides the power supply voltage
P0612, P1262, P0202 and P0203
to No.2 and 3 cylinder injector. The ECM sets the DTC
when faults are detected simultaneously for all the
DTC set condition
injector drive circuits of COMMON 2 system.
None of injector monitor input signal for COMMON
Main trouble symptom 2 system exists approx. for 2.5 seconds or more.
Rough idling
Output lowering
Engine blow up fault is displayed depending on the machine manufac-
Engine stall possible turer.)
Common 2 stop (#2, #3 cylinders stopped), EGR If the intermittent trouble is suspected, the followings
stopped may be the cause.
causes.

system check, List
of Function
3. Connect the DMM between the injector power
2 supply 2 circuit and the ground. 7.0V
H12 Female-side No. 3

3. Disconnect No. 2 and 3 cylinder injector con-
nectors.
3 1.0
4. Measure the resistance between the coupling
connector (H-12) and the injector connector.

Check for installation condition of the injector con-
nector, ECM connector and coupling connec-
tor(H12).


1. Check for the followings in the injector power
supply 2 circuit using breaker box or DMM.
Note:
5 P1262 (Flash code 159) Injection nozzle common 2
Codes.
Open circuit
High resistance

H12 Male-side No.7

3. Measure the resistance between the No. 3 cyl-
7 10M
4H: H94 Male-side No. 6
6H: H95 Male-side No. 7

DMM.
8 Note:
Codes.


DMM.
9 Note:
Codes.

1. Check for installation condition of the injector
connector.

1. Remove the injector connector from the injec-
tor.
No. 2 cylinder, No. 3 cylinder
11 2. Measure the resistance between each injector 10M
terminal and the ground.
or DMM.
12
Note:
Codes.


or DMM.
13
Note:
Codes.

Replace the engine harness.
14
Replace the injector.
Note:
service manual.

necessary.
17 Note:

Replace the ECM.
Note:


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

20 Go to each DTC

Box.
Name
1. Breaker box
2. DMM

5 Open circuit/ Resistance Remove the ECM- 116 Female-side ter- 100 or less 10 M or
high resistance measurement side harness con- minal more
nector from the (H12 No.3)
coupling connec-
tor.
Key switch OFF
Short circuit to Resistance Remove the ECM- 116 GND 10 M or 100 or less
nector from the
coupling connec-
tor.
Key switch OFF

nector from the
coupling connec-
tor.
Key switch OFF
nector from the
coupling connec-
tor.
Key switch OFF
coupling connec-
tor.
Key switch OFF
coupling connec-
tor.
Key switch OFF
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

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 LOW CAN HIGH

TSJJ0039
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
5V 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 5V
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, P1282
puts the signal voltage to the ECM through AP sensor or P1283 is not detected.
signal circuit. When the accelerator opening angle is
large, the AP sensor 1 outputs high voltage, whereas
the AP sensor 2 outputs low voltage.
DTC set condition
Difference in opening angle between accelerator sen- ECM
sors 1 and 2 is 45% or more approx. for 2.5 seconds or
42
more. Accelerator
position 63
sensor
[Accelerator sensor 1 voltage + Accelerator sensor 64
41
2 voltage] is higher than 6.4 V. 20
[Accelerator sensor 1 voltage + Accelerator sensor

2 voltage] is lower than 3.6 V.
100%
The diagnosis lamp does not come on.
Back-up mode 0%
1 system fault: No back-up
2 systems fault: Accelerator opening angle is con-
0.2V 1V 4V
trolled to 0%.
TSHK0159

Refer to 1E-297, List of Diagnostic Trouble Codes may be the cause.
and About recovery from failure in this section for Improper connection of harness connector
The conditions to clear the MIL/DTC Worn harness cladding
The present trouble turns to history trouble when Wire disconnection inside harness cladding
the condition is out of the range from DTC set con- The following inspections are necessary to detect these
dition (recovery from failure). causes.
The diagnosis lamp will go off after the code turns Improper connection of harness connector and
to history trouble and the key switch is turned ECM connector
OFF then ON again. Poor connection of terminal from connector
Using the scan tool, or memory clear switch and Unmatched terminals are fitted.
diagnostic switch operation enables to clear DTCs. Damage of connector lock
Diagnostic aid
Damaged harness
DTC P1271 is detected if the electric potentials on the
ECM terminals No.63 and 64 are not the same (for
example, one of the wiring is disconnected) when Check the relevant items on the scan tool data
accelerator position sensor input is used as an ECM display while moving the connector and the har-
system. ness which are related to the sensor. The varia-
Test description
3. Measure on the harness connector side.

system check, List
of Function
seconds.

3. Check the DTC.
Go to Diagnostic

2. Disconnect the AP sensor connector.
3. Connect the DMM between the sensor power
3 supply terminal of the AP sensor connector 4.7V
and the ground.

3. Short between the sensor power supply termi-
nal of the AP sensor connector and the signal
terminal using jump cable.
5 4. Turn the key switch to ON. 4.7V
5. Check the Accelerator sensor 1 on the data

Is the Accelerator sensor 1 the specified value or

nal of the AP sensor connector and the signal
terminal using jump cable.
6 4. Turn the key switch to ON. 4.7V


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-
7
ator sensor 1-2 comparison fault, List of

1. Check for high resistance in the ground circuit
between ECM and AP sensor using breaker
box or DMM.
8


1. Check for high resistance in the signal circuit
box or DMM.
9

1. Check for high resistance in the signal circuit
box or DMM.
10

3. Check the AP sensor connector terminal for
11 intermittent trouble or poor contact.

2. Remove the ECM.
3. Check the ECM terminals (41, 63, 42, 60, 64,
12 61) for intermittent trouble or poor contact.

Replace the AP sensor.
13
necessary.
15 Note:


Replace the ECM.
Note:

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

18 Go to each DTC
19 4. Connect the DMM between the sensor power 4.7V
supply terminal of the AP sensor connector
and the signal circuit.

About AP sensor Breaker box inspection procedure
Refer to the machines 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
Characteristics of AP sensor Ways to measure voltage and resistance are different
(V) Box.
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM

high resistance measurement sensor connector. sensor power supply more
Key switch OFF terminal

high resistance measurement sensor connector. sensor ground termi- more
Key switch OFF nal

high resistance measurement sensor connector. sensor signal terminal more
Key switch OFF
high resistance measurement sensor connector. sensor signal terminal more
Key switch OFF
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 LOW CAN HIGH

TSJJ0039

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
5V 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 5V DTC set condition
power supply circuit, and grounds to the inside of the AP sensor 1 voltage is 0.2V or less approx. for 0.5
ECM through ground circuit. Also, the AP sensor out- second or 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.
Back-up mode Defective harness routing
1 system fault: No back-up Worn harness cladding
2 systems fault: Accelerator opening angle is con- Wire disconnection inside harness cladding
trolled to 0%. The 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 the specified value or less. 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 the specified
If the intermittent trouble is suspected, the followings value or more when terminals between the AP sensor
may be the cause. connector are shorted, the circuit beyond the sensor is
Improper connection of harness connector normal including ECM.

system check, List
of Function
3 display using a scan tool. 0.2V
Is the Accelerator sensor 1 the specified value or Go to Diagnostic
less? Go to Step 4. aid.
Check the installation condition of the AP sensor
connector and ECM connector.



nal of the AP sensor connector and the sensor
1 signal terminal using jump cable.
5 4.8V

circuit between ECM and AP sensor using
breaker box or DMM.
ator sensor 1 fault (low voltage fault), List of
6 Diagnostic Trouble Codes.
Open circuit
High resistance

box or DMM.
7 Short circuit to AP sensor ground circuit
Open circuit
High resistance

8
necessary.
10 Note:


Replace the ECM.
Note:

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

13 Go to each DTC
14
Check the value for accelerator sensor 1 using a
15 0.2V
3. Check the value for Accelerator sensor 1



If a scan tool or monitor (CAN communication)
is not available, measure the voltage between
17 the sensor power supply terminal and the sen- 4.8V
sor 1 signal terminal of the AP sensor connec-
tor using a DMM.
5. Check for Accelerator sensor 1 on the data
display.

(V) Box.
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
Key switch OFF nal
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 LOW CAN HIGH

TSJJ0039

power supply circuit, and grounds to the inside of the AP sensor 1 voltage is 4.9V or more approx. for
ECM through ground circuit. Also, the AP sensor out- 0.5 second 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 the specified value or more. If less than the
accelerator pedal position sensor and accelerator specified value, identify the cause by referring to Diag-
If the intermittent trouble is suspected, the followings value or less when the AP sensor connector is
may be the cause. removed, the circuit beyond the sensor is normal
Improper connection of harness connector including ECM.

system check, List
of Function
more? Go to Step 4. aid.


5 4. Check the Accelerator sensor 1 on the data 0.1V

less? Go to Step 8. Go to Step 6.

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
Important:
If the AP sensor circuit is shorted to the power

box or DMM.
Open circuit
High resistance

8
necessary.
10 Note:

Replace the ECM.
Note:


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

13 Go to each DTC
14
15 4.9V

Check for installation condition of the AP sensor If the scan tool or
connector, ECM connector and coupling connector. monitor (CAN com-
1. Check for play or looseness in the connection. munication) avail-
able, Go to Step 17.
16 If the scan tool or
Is the fault detected? monitor (CAN com-
munication) is not
available, Go to
Go to Step 12. Step 18.
17 4. Check for Accelerator sensor 1 on the data 0.1V
display.

4. Measure the voltage between the signal termi-
nal and ground terminal of the AP sensor con-
nector using a DMM, and check signal circuit
18 for short circuit to the power supply circuit or
ignition circuit.
Important:
Go to Diagnostic
Is the voltage less than specified value? Go to Step 8. aid.
(V) Box.
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM

high resistance measurement sensor connector. sensor 1 ground termi- more
Key switch OFF nal
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 LOW CAN HIGH

TSJJ0039

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 approx. for 0.5
ECM through ground circuit. Also, the AP sensor out- second or 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 the specified value or less. If more than the
If the intermittent trouble is suspected, the followings value or more when terminals between the AP sensor
may be the cause. connector are shorted, the circuit beyond the sensor is
Improper connection of harness connector normal including ECM.

system check, List
of Function



5 4.8V

circuit between ECM and AP sensor 1 using
breaker box or DMM.
Open circuit
High resistance

between ECM and AP sensor 1 using breaker
box or DMM.
7 Short circuit to AP sensor 1 ground circuit
Open circuit
High resistance

8
necessary.
10 Note:


Replace the ECM.
Note:

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

13 Go to each DTC
14
15 0.2V



If a scan tool or monitor (CAN communication)
is not available, measure the voltage between
17 the sensor power supply terminal and the sen- 4.8V
sor 2 signal terminal of the AP sensor connec-
tor using a DMM.
5. Check for Accelerator sensor 2 on the data
display.

(V) Box.
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
Key switch OFF nal
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 LOW CAN HIGH

TSJJ0039

power supply circuit, and grounds to the inside of the AP sensor 2 voltage is 4.9V or more approx. for
ECM through ground circuit. Also, the AP sensor out- 0.5 second 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 the specified value or more. If less than the
If the intermittent trouble is suspected, the followings value or less when the AP sensor connector is
may be the cause. removed, the circuit beyond the sensor is normal
Improper connection of harness connector including ECM.

system check, List
of Function


5 4. Check the Accelerator sensor 2 on the data 0.1V


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.
Important:

box or DMM.
Open circuit
High resistance

8
necessary.
10 Note:

Replace the ECM.
Note:


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

13 Go to each DTC
14
15 4.9V

Check the installation condition of the AP sensor If the scan tool or
connector and ECM connector. monitor (CAN com-
1. Check for play or looseness in the connection. munication) is avail-
able, Go to Step 17.
16 If the scan tool or
Is the fault detected? monitor (CAN com-
munication) is not
available, Go to
Go to Step 12. Step 18.
17 4. Check for Accelerator sensor 2 on the data 0.1V
display.

4. Measure the voltage between the signal termi-
nal and ground terminal of the AP sensor con-
nector using a DMM, and check signal circuit
18 for short circuit to the power supply circuit or
ignition circuit.
Important:
Go to Diagnostic
Is the voltage less than specified value? Go to Step 8. aid.
(V) Box.
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM

high resistance measurement sensor connector. sensor 1 ground termi- more
Key switch OFF nal
DTC: P1345 (Flash code 16) Cam sensor out of phase
Engine control
module (ECM)

5V 5V
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 108 E-56 107 E-56 109 E-56 95 E-56
EGR valve
EGR valve
18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 1 H-20 2 H-20 4 H-20
0.5 0.5 0.5

O/B T Y 0.75
B/W 0.75 B
0.5 0.5 0.5 0.5 0.5 0.5

2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113 2 E-98 1 E-98 3 E-98
TSJJ0042

The crankshaft position (CKP) sensor generates pulse Key switch input voltage is 18V or more.
when the tooth of the rotor installed to the crankshaft DTC P0335, P0336, P0340, P0341, P1345 or
passes the sensor. Also, the camshaft position (CMP) P1635 is not detected.
sensor, the same as CKP sensor, generates pulse
Cam pulse is normal.
when the pulsar for signal detection installed to the idle
gear D sprocket passes the sensor. Crank pulse is normal.
The ECM sets the DTC when the number of pulses for
CKP sensor and CMP sensor are normal but mutual DTC set condition
pulses do not synchronize. Correct CMP sensor pulse does not exist in crank
gap position.
Behavior does not change during engine running. Action taken when DTC is set
After engine stops, engine will not start. Trouble is displayed on the monitor of the
turer.)
Engine running based on crank when it is normal If the intermittent trouble is suspected, the followings
After engine stops: Unable to identify cylinder may be the cause.
(unable to restart) Improper connection of harness connector
Recovery from failure Worn harness cladding
Refer to 1E-297, List of Diagnostic Trouble Codes Wire disconnection inside harness cladding
Excessive air mixed in the fuel.
causes.
dition (recovery from failure). Poor connection of terminal from connector

system check, List
of Function
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 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.

1. Check that the camshaft gear is installed prop-
erly.

1. Check if the CKP sensor rotor is installed prop-
erly.

1. Clear the DTC.
clear DTCs.

seconds.
set.
4. Check the DTC.

8 Go to each DTC
About CKP sensor About CMP sensor
1 1
2 2
3 3
TSJJ0133 TSJJ0133
Name Name
1. Sensor signal 1. Sensor signal
2. Sensor ground 2. Sensor ground
3. Sensor power supply 3. Sensor power supply
30
15
TSJJ0134 TSJJ0135
Name
1. CMP sensor
About CKP sensor and CMP sensor signals
TSJJ0127
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

The main relay is installed near the blower motor inside Key switch input voltage is 18V or more.
the instrument panel. The ECM turns the main relay DTC P1630 is not detected.
ON when the key switch inputs ON signal, and turns
3 seconds or more has elapsed after key switch
the main relay OFF when the key switch is OFF.
ON.
The battery voltage is supplied to the main relay via
fuse, and turning the main relay ON will supply the Main relay drive indication ON
power supply voltage to the ECM. DTC P1625 or P0606 is not detected.
The ECM sets the DTC when the output to/input from
the main relay do not match. DTC set condition
Main relay input power supply voltage is 1 V or
Main trouble symptom less for 2 seconds or more.
Engine does not start or power supply cannot be shut Relay does not cut off for 5 seconds or more even
off. after the main relay coil OFF command is sent.
Action taken when DTC is set Defective harness routing
Trouble is displayed on the monitor of the Worn harness cladding
machine* or diagnosis lamp comes on. (* Nothing Wire disconnection inside harness cladding
is displayed depending on the machine manufac- The following inspections are necessary to detect these
turer.) causes.
No back-up action Poor connection of terminal from connector
Refer to 1E-297, List of Diagnostic Trouble Codes Poor contact between terminal and wire
The conditions to clear the MIL/DTC Check the relevant items on the scan tool data
Test description
Using the scan tool, or memory clear switch and 4. If the main relay is stuck closed, it is possible to com-
diagnostic switch operation enables to clear DTCs. municate with ECM using a scan tool even with the key
switch OFF.
5. If it is still possible to communicate with ECM using a
Diagnostic aid
scan tool and the DTC is detected when the main relay
If the intermittent trouble is suspected, the followings is removed, the circuit beyond the relay or ECM is
may be the cause. faulty.
Fault in switch body 8. If the Main relay voltage displays the specified
Improper adjustment of switch value or more when terminals between the main relay
installing portion are shorted, the circuit beyond the
relay is normal including ECM.

system check, List
of Function
2. Check the Main relay voltage on the data dis-
3 play using a scan tool. 1V
Is the Main relay voltage the specified value or
4 2. Check the DTC.
Go to Diagnostic
1. Remove the main relay.
2. Check the DTC.
Note:
5 Refer to the machines 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
6
cedure, DTC: P1625 (Flash code 416) Main
relay fault, List of Diagnostic Trouble Codes.

Check the installation condition of the main relay
and ECM connector.


3. Short between the terminals 1 2 and 3 5 in
the main relay installing portion respectively
using jump cable.
5. Check the Main relay voltage on the data dis-

play using a scan tool.
Is the Main relay voltage the specified value or

slow-blow fuse and main relay.
Open circuit

High resistance

main relay and ECM using breaker box or
DMM.
10 Open circuit
High resistance

Replace the main relay.
11

necessary.
13 Note:

Replace the ECM.
Note:

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

16 Go to each DTC
17 1V
4. Connect the DMM between the main relay
connector coil-side terminal and the ground.
18 2. Check the DTC.
Go to Diagnostic
2. Check the DTC.
Note:
19 Refer to the machines 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

Check the installation condition of the main relay
and ECM connector.


22 4. Connect the DMM between the main relay 24V
connector terminal (contact point side) and the
ground.

Box.
Name
1. Breaker box
2. DMM

power supply surement relay. 5 GND
10 Open circuit/ Resistance Disconnect the 2 Relay installing ter- 100 or less 10 M 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 GND more
40 GND
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-297, List of Diagnostic Trouble Codes
Output lowering
Black smoke emitted
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. (* Nothing OFF then ON again.
is displayed depending on the machine manufac- Using the scan tool, or memory clear switch and
turer) diagnostic switch operation enables to clear DTCs.

system check, List
of Function
1. Clear the DTC.
clear DTCs.
seconds.
set.
4. Check the DTC.

necessary.
4 Note:


Replace the ECM.
Note:

6 Go to each DTC
DTC: P1631 (Flash code 55) Voltage fault in 5V 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 LOW CAN HIGH

TSJJ0039

The 5V power supply circuit is provided to the ECM for Key switch power supply voltage is 5.5 V or more,
5 systems. The 5V 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 5V 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. (* Nothing
Idling
Back-up mode
Preconditions when DTC is set Same as accelerator sensor fault
Battery voltage is higher than 16V and lower than Recovery from failure
32V. Refer to 1E-297, 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
to history trouble and the key switch is turned 2. Measure on the harness connector side.
OFF then ON again. 3. Measure on the harness connector side.

system check, List
of Function
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-
4 cedure, DTC: P1631 (Flash code 55) Voltage
fault in 5V power supply 1, List of Diagnostic
Trouble Codes.

1. Check the power supply circuit between AP
sensor 1 and ECM for ground short circuit
cedure, DTC: P1631 (Flash code 55) Voltage
5
Trouble Codes.


necessary.
7 Note:

Replace the ECM.
Note:

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

10 Go to each DTC
Box.
Name
1. Breaker box
2. DMM

4 Short circuit to Voltage mea- Remove the ECM. 42 GND 0V 1 V or more
power supply surement Key switch ON
circuit
5 Short circuit to Resistance Remove the sen- 42 GND 10 M or 100 or less
ground circuit/ measurement sor. more
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 LOW CAN HIGH

TSJJ0039

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. (* Nothing
Due to back-up equivalent to 2000 m (6562 ft)
Black smoke emitted at high altitude Back-up mode
Same as barometric pressure and intake air tem-
Preconditions when DTC is set perature sensor fault
Battery voltage is higher than 16V and lower than
32V. Refer to 1E-297, List of Diagnostic Trouble Codes

system check, List
of Function
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 the specified value or less? Go to Step 5.

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.

1. Check the power supply circuit between baro-
metric pressure sensor and ECM for ground
short circuit using breaker box or DMM.
5
Trouble Codes.


necessary.
7 Note:

Replace the ECM.
Note:

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

10 Go to each DTC
Box.
Name
1. Breaker box
2. DMM

circuit

5V
Engine coolant Vcc

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
0.75 0.75 0.75
B/Y L/Y W/B
Pulse 0.75 0.75 0.75 0.75

box 2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
Engine
coolant
temperature
pressure sensor
A
0.75
R
4 H-6 37 E-57 18 E-57

Vehicle
speed sensor
A
Meter
Machine
control
unit
coolant
temperature
gauge
Machine trouble
diagnosis monitor
TSJJ0036

The 5V power supply circuit is provided to the ECM for DTC P1630 is not detected.
5 systems. The 5V power supply circuit 3 supplies Battery voltage is higher than 16V and lower than
power to the engine oil pressure sensor. 32V.
The ECM sets the DTC when the voltage in the 5V
power supply circuit 3 is higher or lower than the nor- DTC set condition
mal range.
Key switch power supply voltage is 5.5 V or more,
Main trouble symptom or 4.5 V or less for 0.5 seconds or more.
Black smoke emitted at starting everytime Action taken when DTC is set
Noise deteriorates. Trouble is displayed on the monitor of the
White smoke emitted at low temperatures. machine* or diagnosis lamp comes on. (* Nothing
Rough idling is displayed depending on the machine manufac-
Stall turer.)
Back-up mode The diagnosis lamp will go off after the code turns
Same to oil pressure, coolant temperature, and
OFF then ON again.
combustion temperature sensor fault
Recovery from failure diagnostic switch operation enables to clear DTCs.
Test description
recovery from failure. Numbers below indicate step numbers in the chart.
The conditions to clear the MIL/DTC 3. Measure on the harness connector side.

system check, List
of Function
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.
4 Trouble Codes.
Note:
P1633 (Flash code 55) Voltage fault in 5V power
supply 3, List of Diagnostic Trouble Codes.


1. Check the power supply circuit between
engine oil pressure sensor and ECM for
ground short circuit using breaker box or
DMM.
Trouble Codes.
5
Note:

necessary.
7 Note:

Replace the ECM.
Note:

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

10 Go to each DTC
Box.
Name
1. Breaker box
2. DMM
Step Item to be Checking Measuring condition Measuring Terminal Normal Abnormal

circuit
open circuit.
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine control
CKP sensor 5V
5V
Boost temperature
sensor signal
108 E-56 107 E-56 74 E-56 109 E-56 91 E-56 95 E-56
3 H-20 1 H-20 2 H-20 4 H-20 15 H-20 17 H-20 16 H-20 8 H-20
0.75 B
0.5 0.5 0.5

W/B Gr/B V/W 0.75 0.75 0.75 0.75 0.75
B/R R/L R/L L R/W
2 E-98 1 E-98 3 E-98 2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

CKP sensor (MRE)
TSJJ0037

power to the boost pressure sensor.
power supply circuit 4 and 3 is higher or lower than the
normal range. machine* or diagnosis lamp comes on. (* Nothing
Black smoke emitted
Back-up mode
Preconditions when DTC is set Same as boost pressure and boost temperature
DTC P1630 is not detected. sensor fault
Battery voltage is higher than 16V and lower than
32V. Recovery from failure

system check, List
of Function
tor.
2 3. Connect the DMM between the boost pressure 5.5V
sensor power supply terminal and the ground.

tor.
3 3. Connect the DMM between the boost pressure 4.5V
sensor power supply terminal and the ground.

1. Check the power supply circuit between boost
the battery power supply circuit or ignition
power supply circuit using breaker box or
DMM.
4 Trouble Codes.
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.
7 Note:

Replace the ECM.
Note:

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

10 Go to each DTC
Box.
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)
EGR EGR EGR

5V
B+ B+ B+
101 E-56 98 E-56 87 E-56 100 E-56 82 E-56 90 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
4 H-8 2 H-8 6 H-8 3 H-8 7 H-8 1 H-8 5 H-8 8 H-8

18 H-20 5 H-20 19 H-20 6 H-20 14 H-20 13 H-20 12 H-20
0.5 0.5 0.5
O/B T Y 0.75
B/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
0.5 0.5 0.5

L/W Br L 1 E-80 3 E-80 7 E-80 2 E-80 6 E-80 4 E-80 8 E-80 5 E-80
2 E-112 1 E-112 3 E-112 1 E-113 2 E-113 3 E-113

V
W U
TSJJ0038

power to the common rail pressure sensor and the
EGR position sensor. Action taken when DTC is set
The ECM sets the DTC when the voltage in the 5V
power supply circuit 5 and 2 is higher or lower than the machine* or diagnosis lamp comes on. (* Nothing
normal range. is displayed depending on the machine manufac-
turer.)
Output lowering Back-up mode
Engine stall possible Same as rail pressure sensor fault and EGR posi-
Exhaust gas is affected. tion sensor fault
Preconditions when DTC is set Recovery from failure

DTC P1630 is not detected. Refer to 1E-297, List of Diagnostic Trouble Codes
Battery voltage is higher than 16V and lower than and About recovery from failure in this section for
32V. recovery from failure.

system check, List
of Function
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.
4 Trouble Codes.
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.
7 Note:

Replace the ECM.
Note:

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

10 Go to each DTC
Box.
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
81 E-57 4 E-57 3 E-57 1 E-57 43 E-57 62 E-57 52 E-57 38 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150 14 FL-150 6 FL-150
CAN CAN
LOW HIGH
DLC
5 FL-150 4 FL-150
CAN LOW CAN HIGH
TSJJ0033

The ECM communicates with the machine control unit Key switch input voltage is 20 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 is displayed depending on the machine manufac-
and inputs must always be the same. turer.)
The ECM sets the DTC when the fault is detected for
the CAN communication.
Back-up mode
Main trouble symptom Varies depending on the machine manufacturer
Specified engine speed (depending on the machine
manufacturer)
DTC set condition and About recovery from failure in this section for
Bus-off detection continues for 3 seconds
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
If the intermittent trouble is suspected, the followings ness which are related to the sensor. The varia-
may be the cause. 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 2. If no DTC is detected, intermittent trouble is sus-
The following inspections are necessary to detect these pected. Identify the cause by referring to Diagnostic
causes. aid.
ECM connector

Perform the OBD check. Go to 1E-262, OBD
system check, List
of Function
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 70
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. 120
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. 120
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.
8 Refer to 1E-649, Breaker box inspection pro-
cedure, DTC: U2104 (Flash code 84) CAN Bus
fault, List of Diagnostic Trouble Codes.
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
9 fault, List of Diagnostic Trouble Codes.
Open circuit
High resistance
2. If the fault is detected, repair as required. Replace the
machine control
Is the fault detected? Go to Step 2. unit.
necessary.
11 Note:

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.

14 Go to each DTC
Remove the ECM, and measure the resistance
between the CAN-High-side terminal and CAN-
15 Low-side terminal of the ECM connector. Approx. 120

1. Install the ECM, and remove the machine con-
trol unit.
16 High-side terminal and CAN-Low-side terminal Approx. 120
of the machine control unit connector.

Box.
Name
1. Breaker box
2. DMM

8 Short circuit to Voltage mea- Remove all the rel- 18 GND 0V 18 V or
power supply surement evant ECU con- 37 GND more
circuit nectors.
Key switch ON
9 Open circuit/ Resistance Remove all the rel- 37 Machine control 100 or less 10 M 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 GND 10 M or 100 or less
ground measurement evant ECU con- 37 GND more
nectors.
Key switch OFF
DTC: U2106 (Flash code 85) CAN timeout fault
Engine control
module (ECM)
CAN LOW CAN HIGH
KWP2000
81 E-57 4 E-57 3 E-57 1 E-57 43 E-57 62 E-57 52 E-57 38 E-57 37 E-57 18 E-57
1 FL-150 7 FL-150 14 FL-150 6 FL-150
CAN CAN
LOW HIGH
DLC
5 FL-150 4 FL-150
CAN LOW CAN HIGH
TSJJ0033

The ECM communicates with the machine control unit DTC U2104 is not detected.
(ECU) through CAN communication circuit. The ECM Key switch input voltage is 20 V or more.
data outputs through the CAN-High circuit, and other
ECU data inputs through the CAN-Low circuit. The Action taken when DTC is set
CAN communication performs at a constant speed
without interruption, and the number of data outputs Trouble is displayed on the monitor of the
and inputs must always be the same. machine* or diagnosis lamp comes on. (* Nothing
The ECM sets the DTC when the CAN communication is displayed depending on the machine manufac-
is disrupted with the machine control unit (ECU). turer.)

Specified engine speed* (* depending on the Varies depending on the machine manufacturer
machine manufacturer)
DTC set condition Refer to 1E-297, List of Diagnostic Trouble Codes
Revolution command message of CAN communi- and About recovery from failure in this section for
cation is disrupted for 1 second or more. recovery from failure.
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.
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
may be the cause. Check the relevant items on the scan tool data
Wire disconnection inside harness cladding Test description
The following inspections are necessary to detect these Numbers below indicate step numbers in the chart.
causes. 2. If no DTC is detected, intermittent trouble is sus-
pected. Identify the cause by referring to Diagnostic
aid.

system check, List
of Function
seconds.

3. Check the DTC.
Go to Diagnostic
1. Check for the followings in the CAN-Low circuit
machine control unit (ECU) using breaker box
or DMM.
cedure, DTC: U2106 (Flash code 85) CAN tim-
3 eout fault, List of Diagnostic Trouble Codes.
Open circuit
High resistance

1. Check for the followings in the CAN-Low circuit
machine control unit (ECU) using breaker box
or DMM.
cedure, DTC: U2106 (Flash code 85) CAN tim-
4 eout fault, List of Diagnostic Trouble Codes.


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.
9 Note:

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.

12 Go to each DTC

Box.
Name
1. Breaker box
2. DMM

4 Open circuit/ Resistance Remove the 18 Machine control 100 or less 10 M 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 GND 10 M or 100 or less
ground measurement machine control 37 GND more
unit (ECU) connec-
tor.
Key switch OFF
Short circuit to Voltage mea- Remove the 18 GND 0V 18 V or
power supply surement machine control 37 GND more
circuit unit (ECU) connec-
tor.
Key switch ON
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
machines 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
machines 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
Before using this paragraph, perform the 1E-262, OBD
system check, List of Function Checks and check all
the following items.
OUT
Check if excessive load is applied to the machine IN Fuel-filter
side.
Electromagnetic
ECM and diagnosis lamp operate properly.
pump
Check the DTC. Pre-filter
Scan tool data shows normal operating range.

Check the condition of the machine to identify the
applicable symptom from List of trouble symp-
tom. Perform the procedure described in the IN
OUT
symptom chart.
Check with the customer if correct engine oil and Pre-filter Electromagnetic
fuel are used. pump
Fuel-filter
Visual check TSHK0171
Careful visual check is required for some symptom pro- Check that Isuzu genuine pre-filter is arranged so
cedures. By this check, the problem can be corrected that air flow is not blocked, since the air bleeding
without performing further check, and time can be plug is not installed on it.
saved. Also, check that the layout of inlet and outlet of the
This check includes the following items. electromagnetic pump is proper. Correct the layout
There is no dirt or clogging in fuel filter. if the inlet of the electromagnetic pump faces
There is no poor contact in connector (it must be upward or outlet of it faces in the direction that the
connected with click sound). Especially for CKP machine moves to.
sensor and CMP sensor. Fuel system is free from oil leakage, and pipe is
The terminal voltage of battery is not low. not damaged or dent.
Wire is connected properly, tightened securely or Intake system parts for fault.
not cut. Exhaust system parts for fault.
Commercial accessory power supply is not bifur-
cated from ECM power supply. Diagnostic aid
ECM ground is not contaminated and installed to Important:
the proper position securely. If the crank sensor is faulty, crank more than
Pipes and hoses relevant to fuel, air and oil are 60 rpm for 14 seconds or more since it is not
free of crack or twist, and are properly connected. judged on cranking for less than 14 revolu-
Thoroughly check for any oil leakage and clogging. tions.
The layout of the fuel filter, pre-filter and electro- When the engine is running at low speed, the
magnetic pump does not block air flow. DTC of crank sensor fault may not be detected.
If an intermittent trouble is found, raise the
engine speed up to No Load Max, and check if
DTC related to crank sensor is detected.
Fuel system fault (run out of fuel, frozen fuel, air

mixed in fuel pipe, faulty filter [clog in main filter,
gauze filter], pipe fault, fuel quality, fuel tank [for-
eign matter, fuel suction fault])
Intake system fault (clogging in filter, intake pipe
fault, etc.)
Using low-viscosity fuel such as kerosene might
cause an excessive wear at supply pump plunger
part which may result in a faulty discharging and a
faulty starting. In this case, the supply pump is
needed to be replaced.
When an engine start failure occurs, confirm with
the customer the fuel type. The same problem will
reoccur even after a replacement of the pump if a
low-viscosity fuel like kerosene is in use, so advise
Absolute pressure
the customer not to use a low-viscosity fuel.
Oil mixed with fuel which has been stored for a
long period of time and bio-fuel mixture which con- Non-criteria range P0087 criteria range
tains organic matter have a tendency to oxidize.

Oxidized fuel may cause an excessive wear at
15MPa
parts related to the camshaft in the supply pump, (2176psi)
and this might lead to an engine start failure
caused by a faulty discharging. In this case, the
supply pump is needed to be replaced. Range in P0087 is established
Replacing a supply-pump will cost if the customer

was using a oil mixed with fuel which has been
stored for a long period of time and bio-fuel mixture 900
Engine speed (rpm)
which contains organic matter, so advise the cus-
tomer not to use those types of fuel.
TSHK0163
When using a highly moistured fuel, add a large
Common rail fault (flow damper or pressure limiter
sedimenter to pre-fuel filter to avoid the moist mix-
is activated/, degradation of sealability)
ing into the fuel system.
Injector fault (no fuel injection)
Supply pump fault (no fuel pressure feed)
ECM judgment on the DTC for no fuel pressure System down due to trouble
feed in supply pump is detected when the engine Engine body trouble
speed is 900 rpm, and the absolute pressure lower (seizure, compression pressure shortage, other
than 15 MPa (2176 psi) holds 3 seconds or more. mechanical trouble)
Therefore, the DTC is not detected if the engine ACG trouble
does not start due to no fuel pressure feed in faulty Machine side related equipment trouble
supply pump. (oil pressure pump etc.)
Effect of commercial electrical equipment (radio,
lamp, etc.)
Engine speed (rpm)
ECM trouble
(body, power supply, ground, etc.)
P0087 Judgment required engine speed
the harness for loosened wire causing short circuit
900
to other circuits. Also, perform the function diagno-
sis to check the operation and control of each part.
Repair if faulty.
Minimum firing engine speed

80
60
System realization engine speed
TSHK0162

Check that fuel in the fuel tank is proper quantity.
1
Is fuel in the fuel tank sufficient? Go to Step 2. Add the fuel.
2 OFF, then Go to

Check if the overheating switch is installed, and
check the switch for faults.
Did the ECM stop the engine in an emergency
3 due to faults in the harness or switches?
If the trouble is detected, repair or replace.

system check, List
of Function
Check if following DTCs are detected.
5 DTC: P0335, P0336, P0340, P0341, P0601,
P1261, P1262 Go to the related
Inspection method
Is DTC detected? by DTC. Go to Step 6.
Check the crank speed.
Check if the crank speed is more than the neces-
6 sary speed for ECM to identify engine rotation. 60 rpm
Is the crank speed the specified value or more? Go to Step 7. Go to Step 8.

Check the crank speed.
Check if the crank speed is more than the neces-
7 sary speed to start the engine (first combustion). 80 rpm
Is the crank speed the specified value or more? Go to Step 8. Go to Step 11.
9 4351 psi) 0
Check if DTC for common rail pressure sensor is
10 detected. Go to each DTC
Is DTC detected? diagnosis. Go to Step 12.
Check the starting system. Go to 1E-281,
Starting system

gauze filter)
Fuel tank (pump strainer)
Fuel system pipe
2. Check fuel discharge.
Important:
procedure, Engine start failure, List of Trouble
12 Symptom.
ature)
If opaque frosty object is found in the filter
part of the main filter, waxing may occurs.
Replace fuel.
Use of summer fuel in cold region may
cause fuel to be frozen. Attention is needed
especially if it is carried by ship to the
regions where has different climates or
temperatures.
5. Repair or replace the faulty part.

Restore all the removed parts, and start the engine.
13
Does the engine start? Verify repair. Go to Step 14.
Check the injector.
1. Clear the DTC.
clear DTCs.
3. Select the Actuator test from the scan tool
menu.
15 When the scan tool is not available, refer to
1E-89, 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.
18 Note:
Refer to the machines manual for charge warning.
Does the charge warning operate? Go to Step 20. Go to Step 19.

Replace the ACG. Also, check the charge warning
19 system, and repair or replace if faulty.
Check the condition of commercial electrical equip-
ment such as radio and lights.
20
Does the engine start when the commercial electri-
cal equipment is powered OFF? Go to Step 21. Go to Step 22.
Correct the installation condition of the electrical
21 equipment, or remove the electrical equipment.
Check the mechanical part of the engine, and
repair if faulty.
Compression pressure
Valve system
Injector
22 Timing gear/timing chain
Related parts of piston/crank
Note:
service manual.


necessary.
24 Note:

Replace the ECM.
Note:
Fuel discharge inspection procedure

side in the following procedure. 6
1. Disconnect the fuel line from the inlet of the supply 5

4
pump.
2. Activate the electromagnetic pump. 3

mixed in fuel.
TSHK0164
Name
1. Supply pump
2. Fuel tank
3. Pre-fuel filter
5. Fuel filter
ply pump.
Note:
5
3
procedure.
6
5
4
1
3 2
TSHK0167
Name
1. Supply pump
2. Fuel tank
3. Pre-fuel filter
5. Fuel filter
2
TSHK0165
Name
1. Supply pump
2. Fuel tank
3. Pre-fuel filter
5. Fuel filter
6. Clear pipe
Electromagnetic pump inspection procedure 3. Blow air into the inlet of the electromagnetic pump
with your mouth.
in the fuel hose. The internal seal may be stuck. Blow air to elim-
inate sticking.
It is normal if pulsation exists.
2
and check again from Step 1.
replace the pump.
1
TSHK0107
2
Name
1. Fuel inlet port
2. Fuel outlet port

3
Step 1.
TSHK0106
Name
2. + terminal
3. - terminal
Engine stall
Pre-inspection
the following items.
OUT
IN Fuel-filter
Important:
To detect crank sensor fault, crank more than Electromagnetic
60 rpm for 14 seconds or more since it is not pump
Pre-filter
judged on cranking for less than 14 revolu-
tions.
When the engine is running at low speed, the
DTC of crank sensor fault may not be detected.
If an intermittent trouble is found, raise the IN
OUT
engine speed up to No Load Max, and check if
DTC related to crank sensor is detected. Pre-filter Electromagnetic
pump
Check if excessive load is applied to the machine Fuel-filter
side. TSHK0171

Check that Isuzu genuine pre-filter is arranged so
Check the DTC.
that air flow is not blocked, since the air bleeding
Scan tool data shows normal operating range. plug is not installed on it.
Check the condition of the machine to identify the Also, check that the layout of inlet and outlet of the
applicable symptom from List of trouble symp- electromagnetic pump is proper. Correct the layout
tom. Perform the procedure described in the if the inlet of the electromagnetic pump faces
symptom chart. upward or outlet of it faces in the direction that the
Check with the customer if correct engine oil and machine moves to.
fuel are used. Intake system parts for fault.
Check that the tank has fuel. Exhaust system parts for fault.
Visual check Diagnostic aid

Careful visual check is required for some symptom pro- Fuel system fault (run out of fuel, frozen fuel, air
cedures. By this check, the problem can be corrected mixed in fuel pipe, faulty filter [clog in main filter,
without performing further check, and time can be gauze filter], pipe fault, fuel quality, fuel tank [for-
saved. eign matter, fuel suction fault])
This check includes the following items. Intake system fault (clogging in filter, intake pipe
There is no poor contact in connector (it must be fault, etc.)
connected with click sound). Especially for CKP Supply pump fault (no fuel pressure feed)
sensor and cam sensor. ECM judgment on the DTC for no fuel pressure
Wire is connected properly, tightened securely or feed in supply pump is detected when the engine
not cut. speed is 900 rpm, and the absolute pressure lower
Commercial accessory power supply is not bifur- than 15 MPa (2176 psi) holds 3 seconds or more.
cated from ECM power supply. Therefore, the DTC is not detected if the engine
does not start due to no fuel pressure feed in faulty
ECM ground is not contaminated and installed to
supply pump.
the proper position securely.
Pipes and hoses relevant to fuel, air and oil are
free of crack or twist, and are properly connected.
Thoroughly check for any oil leakage and clogging.
Fuel system is free from oil leakage, and pipe is
not damaged or dent.
The layout of the fuel filter, pre-filter and electro-
magnetic pump does not block air flow.
Common rail fault (flow damper or pressure limiter
is activated/, degradation of sealability)
Injector fault (no fuel injection)
Engine speed (rpm)
System down due to trouble

Engine body trouble
(seizure, compression pressure shortage, other
mechanical trouble)
P0087 Judgment required engine speed
900 ACG trouble
Machine side related equipment trouble
(oil pressure pump etc.)
Minimum firing engine speed lamp, etc.)
80
ECM trouble
60
System realization engine speed (body, power supply, ground, etc.)
TSHK0162 the harness for loosened wire causing short circuit
Repair if faulty.
Absolute pressure
Non-criteria range P0087 criteria range
15MPa
(2176psi)
Range in P0087 is established
900
Engine speed (rpm)
TSHK0163

system check, List
of Function
Check if excessive load is applied to the machine
side.
2 Note:
Refer to the machines manual for check and
repair.


Check the electrical system.
1. Check the DTC of crank sensor.
Important:
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 to perform
the test drive.
2. Check the connectors of the ECM, fuel pump,
3 ACG and electronic governor for poor contact
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 machines 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.
next step.

scan tool.
next step.



1. Replace the SCV.
Refer to 1E-213, SCV Replacement proce-
dure, Engine component location diagram,
12 Engine Control System in this section for the
SCV replacement procedure.
Is the symptom improved? Verify repair. Go to Step 13.

gauze filter)
Fuel tank (pump strainer)
13 Fuel system pipe
ature)

Check the intake system. Go to 1E-288,
Intake system
Check the exhaust system. Go to 1E-288,
Exhaust system
repair if faulty.
Valve system
16 Injector
Timing gear/timing chain


necessary.
18 Note:

Replace the ECM.
Note:

Engine hunting, rough idling
Pre-inspection Check that Isuzu genuine pre-filter is arranged so
that air flow is not blocked, since the air bleeding
plug is not installed on it.
the following items. Also, check that the layout of inlet and outlet of the
electromagnetic pump is proper. Correct the layout
ECM and diagnosis lamp operate properly. if the inlet of the electromagnetic pump faces
Check the DTC. upward or outlet of it faces in the direction that the
Scan tool data shows normal operating range. machine moves to.
Check the condition of the machine to identify the Intake system parts for fault.
applicable symptom from List of trouble symp- Exhaust system parts for fault.
tom. Perform the procedure described in the
symptom chart. Diagnostic aid
Check with the customer if correct engine oil and Fuel system fault (run out of fuel, frozen fuel, air
fuel are used. mixed in fuel pipe, faulty filter [clog in main filter,
Visual check eign matter, fuel suction fault])
Careful visual check is required for some symptom pro- Intake system fault (clogging in filter, intake pipe
cedures. By this check, the problem can be corrected fault, etc.)
without performing further check, and time can be Supply pump (including feed pump) fault (no fuel
saved. pressure feed)
This check includes the following items.
Switch input circuit system fault
There is no poor contact in connector (it must be
Sensor input circuit system fault (accelerator posi-
connected with click sound).
tion (AP) sensor, harness, engine coolant temper-
The terminal voltage of battery is not low. ature (ECT) sensor, etc.)
Wire is connected properly, tightened securely or AP sensor system fault (sensor, harness, etc.)
not cut.
Engine body fault (seizure, compression pressure
Commercial accessory power supply is not bifur- shortage, other mechanical trouble)
cated from ECM power supply.
Machine side related equipment trouble (oil pres-
ECM ground is not contaminated and installed to sure pump etc.)
Pipes and hoses relevant to fuel, air and oil are lamp, etc.)
Fuel system is free from oil leakage, and pipe is the harness for loosened wire causing short circuit
not damaged or dent. to other circuits. Also, perform the function diagno-
The layout of the fuel filter, pre-filter and electro- sis to check the operation and control of each part.
magnetic pump does not block air flow. Repair if faulty.
OUT
IN Fuel-filter
Electromagnetic
pump
Pre-filter
IN
OUT
Pre-filter Electromagnetic
pump
Fuel-filter
TSHK0171

system check, List
of Function
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 27. Go to Step 4.

Bleed air from fuel, and check for trouble symptom
again.
Note:

Intake system
Check the fuel system. Go to 1E-284, Fuel
system check, List
of Function
1. Check if the machine has the APS. On the
machine with APS, throttle opening angle and
idle speed vary as idling input voltage varies
around 1.05 V.
And if the APS learning control was set, that
would cause vibrations from the throttle open-
ing angle and idle speed fluctuations at every
ignition cycle.
2. With the key switch ON, check the idling volt-
age for variation.
If the voltage varies, check the input side of
7 APS for any problems.
3. Check the idling voltage values at the key
switch ON and OFF each.
Note:
If the voltage values at ON and OFF are different,
contact the ISUZU dealer since idling learning con-
trol may be the cause.
5. Restore all the parts and start the engine.
Is the idling vibration improved? Verify repair. Go to Step 8.


Check the injector.
1. Clear the DTC.
clear DTCs.
menu.


Note:
service manual.

Check for the engine symptom again.
12
13
Does the engine symptom change when the com-
mercial electrical equipment is powered OFF? Go to Step 14. Go to Step 15.
position (CKP) sensor and camshaft position
(CMP) sensor.
15 Check the CKP sensor and CMP sensor for
improper installation such as play.
Is it properly installed? Go to Step 17. Go to Step 16.

Correct the installation conditions of the CKP sen-
16 sor and CMP sensor.

Check the signal conditions of CKP sensor and
CMP sensor using a scan tool.
18 2. Crank the engine.
3. Correct the data list on the scan tool.
Is the speed displayed? Go to Step 21. Go to Step 19.

Check for signal detection condition of the CKP
sensor.
2. Remove the harness from the CMP sensor.
19
(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 26. Go to Step 20.

Check for signal detection condition of the CMP
sensor.
2. Remove the harness from the CKP sensor.
20 (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 26. Go to Step 21.

21
necessary.
23 Note:

Replace the ECM.
Note:


Restore the ECM to its original condition of before
replacement.
Note:
25 replacing or rewriting the ECM.

repair if faulty.
Valve system
26 Flywheel
Camshaft gear

Repair the machine, and check the repair.
27
Engine output shortage
Pre-inspection Exhaust system fault (exhaust brake, exhaust pipe
fault, etc.)
system check, List of Function Checks and check all Sensor input circuit system fault (accelerator posi-
the following items. tion (AP) sensor, harness, etc.)
ECM and diagnosis lamp operate properly. Switch input circuit system fault
Check the DTC. Engine body fault (compression pressure, valve
clearance, turbocharger, supply pump, injector,
common rail and other mechanical trouble, etc.)
Machine side related equipment trouble (oil pres-
sure pump etc.)
symptom chart. Effect of commercial electrical equipment (radio,
Check with the customer if correct engine oil and lamp, etc.)
fuel are used. Check the connector for poor contact, the harness
Various kinds of causes are assumed for output short- for fault such as wear or bend, and the wire inside
age, therefore thoroughly investigate the relation the harness for loosened wire causing short circuit
between engine body and machine. to other circuits. Also, perform the function diagno-
Check what operation triggers the output shortage.
Repair if faulty.
If hesitations or lag down is included in the symptom of
the output shortage, the fault is related to the machine- Output lowering due to regulated fuel flow during
side control. Contact with the machine manufacturer. overheat
If Tech2 is available, checking the boost of a rated Output shortage due to regulated fuel flow at high
point enables to check the engine output at rated point altitude
as a simplified method.
Control during overheat
Visual check In overheating, ECM begins to limit fuel flow when the
Careful visual check is required for some symptom pro- engine coolant temperature exceeds 100C (212F),
cedures. By this check, the problem can be corrected for engine protection. It limits fuel flow further as the
without performing further check, and time can be engine coolant temperature goes up. Fuel flow is lim-
saved. ited to a certain level at around 120C (248F)*. (* Set-
This check includes the following items. ting varies depending on the machine manufacturer)
The system raises an alarm from 105C (221F) for
There is no dirt or clogging in air cleaner element.
some machines. In addition to alarm, by reducing the
Wire is connected properly, tightened securely or load to the machine, it enables to avoid such conditions
not cut. that the fuel flow is limited.
Commercial accessory power supply is not bifur-
ECM ground is not contaminated and installed to
Pipes and hoses relevant to fuel, air and oil are
Thoroughly check for any oil leakage and clogging. 100%
100 (212 )

Fuel fiow
Increase in resistance due to dirt or clogging in

intake system parts (especially air cleaner ele- Warning (248 )
indication
ment) and crushed intake pipes
DTC set
Exhaust system parts for fault.
Diagnostic aid 110

(221 ) (230 )
Engine coolant temperature
mixed in fuel pipe, faulty filter [clog in main filter, TSHK177
Intake system fault (clogging in filter, intake pipe
fault, etc.)
About high-altitude correction
ECM calculates the current altitude based on the baro-
metric pressure sensor signal.
It regulates the opening/closing period of SCV 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

system check, List
of Function
1. Make sure that the engine coolant temperature
does not exceed 100C (212F).
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. machine manufac-
turer for counter-
Did you drive at high altitude? measure. 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:


system check, List
of Function
Intake system
Exhaust system
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.
menu.


Note:
service manual.


necessary.
19 Note:

Replace the ECM.
Note:

replacement.
Note:
21 replacing or rewriting the ECM.

repair if faulty.
Valve system
22 Injector

Check the machine-side equipment (trouble of oil
23 pressure pump etc.), and repair if faulty.
24
Exhaust gas contains a lot of white smoke.
Pre-inspection Pipes and hoses relevant to fuel, air and oil are
the following items. Fuel system is free from oil leakage, and pipe is
Check the DTC. Intake system parts for fault.
Exhaust system parts for fault.
Check the condition of the machine to identify the Diagnostic aid
tom. Perform the procedure described in the Fuel quality (when using fuel with low cetane
symptom chart. value, other than specified)
Using low-viscosity fuel such as kerosene will
Check with the customer if correct engine oil and
cause an excessive wear at seat part of the injec-
fuel are used.
tor to be abnormal spray, and white smoke may be
emitted. In this case, injector is needed to be
Visual check
replaced.
Careful visual check is required for some symptom pro- Replacing the injector will cost if the customer was
cedures. By this check, the problem can be corrected using low viscosity fuel such as kerosene, so
without performing further check, and time can be advise the customer not to use those types of fuel.
saved. Long-term idling
Trouble of engine coolant temperature (ECT) sen-
There is no poor contact in injector connector (it sor, fuel temperature (FT) sensor, intake air tem-
must be connected with click sound). perature (IAT) sensor, boost pressure sensor, or
Wire is connected properly, tightened securely or barometric pressure sensor.
not cut. Engine body trouble (compression pressure short-
Commercial accessory power supply is not bifur- age, related to piston, turbocharger, rise/decline of
cated from ECM power supply. oil, etc.)
ECM ground is not contaminated and installed to ECM trouble (body, power supply, ground, etc.)

system check, List
of Function
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

system check, List
of Function
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 menu.

Perform the pre-injection stop test.
1. Select the Stop pre-injection from the scan
tool menu to perform the test.
2. Check for change of the engine vibration and
7 engine sound.
If they did not change, it can be judged that
pre-injection does not occur.
Did the engine vibration and engine sound

change? Go to Step 9. Go to Step 10.

Note:
service manual.

10
Check the fuel quality.
Ask the customer if using low viscosity fuel
11 such as kerosene.
Is it low viscosity fuel such as kerosene? Go to Step 12. Go to Step 13.


Replace the all injectors.
Note:
service manual.
Using low viscosity fuel will cause an excessive
12 wear at seat part of the injector to cause abnor-
mal spray. Abnormal spray causes white
smoke.
Start the engine, and check the condition of the
exhaust gas.
Is the condition of the exhaust gas normal? Go to Step 13.

necessary.
14 Note:

Replace the ECM.
Note:

16 replacement.
repair if faulty.
Valve system
17 Injector

18
Exhaust gas contains a lot of black smoke.
Pre-inspection Commercial accessory power supply is not bifur-
system check, List of Function Checks and check all ECM ground is not contaminated and installed to
the following items. the proper position securely.
ECM and diagnosis lamp operate properly. Pipes and hoses relevant to fuel, air and oil are
Check the DTC. free of crack or twist, and are properly connected.
Check the condition of the machine to identify the not damaged or dent.
Intake system parts for fault.
symptom chart. Exhaust system parts for fault.
fuel are used. Diagnostic aid
Fuel quality (use of fuel other than specified)
Visual check Intake system fault (clogging in filter, intake pipe
Careful visual check is required for some symptom pro- fault, etc.)
cedures. By this check, the problem can be corrected EGR control system fault
without performing further check, and time can be Exhaust system fault (exhaust pipe fault etc.)
saved.
Engine coolant temperature (ECT) sensor fault
Boost pressure sensor fault (sensor, pipe, etc.)
There is no dirt or clogging in air cleaner element.
Engine body trouble (compression pressure short-
Wire is connected properly, tightened securely or
age, related to the piston, turbocharger, rise of oil)
not cut.
EGR valve missing

system check, List
of Function
Intake system
Check the EGR control system. Go to 1E-289, EGR
control system
system check, List
of Function
Exhaust system
6
repair if faulty.
7 Valve system (valve clearance)

8

necessary.
10 Note:

Replace the ECM.
Note:

12
repair if faulty.
Valve system
13 Injector

14
EGR valve check
TSJJ0138

Noise
Pre-inspection Pipes and hoses relevant to fuel, air and oil are
the following items. Fuel system is free from oil leakage, and pipe is
Check for noise by referring to the machines man-
ual. Intake system parts for fault.
ECM and diagnosis lamp operate properly. Exhaust system parts for fault.
Check the DTC.
Diagnostic aid
mixed in fuel pipe, faulty filter [clog in main filter,
applicable symptom from the table of contents.
Perform the procedure described in the symptom
chart.
Intake system fault (EGR valve fault)
fuel are used. Injector fault (no fuel injection)
Engine body fault (seizure, compression pressure
Visual check shortage, other mechanical trouble)
Careful visual check is required for some symptom pro- Machine side related equipment trouble (oil pres-
cedures. By this check, the problem can be corrected sure pump etc.)
without performing further check, and time can be ECM trouble (body, power supply, ground, etc.)
saved. This check includes the following items. Check the connector for poor contact, the harness
Wire is connected properly, tightened securely or for fault such as wear or bend, and the wire inside
not cut. the harness for loosened wire causing short circuit
ECM ground is not contaminated and installed to to other circuits. Also, perform the function diagno-
the proper position securely. sis to check the operation and control of each part.
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 3.
Check if the noise is the high-frequency sound gen-
erated from the exhaust system.
The high frequency sound from the exhaust system
may be caused by the turbine revolution.
2 The silencer may not have high-frequency noise
reduction. Contact the ISUZU dealer for the specifi-
cation of silencer.
Is it without high-frequency noise reduction? Go to Step 3.

Perform the pre-injection stop test.
Select the Stop pre-injection from the scan tool
4 menu to perform the test.

Perform Injection Stop for Each Injector.
menu.
5

Note:
service manual.

Check the EGR valve.
Fault in EGR valve body
7 Repair or replace the faulty part.

Refer to Engine section in the service manual to
check the engine trouble.


Fuel consumption deteriorates.
Pre-inspection Visual check
Before using this paragraph, perform the 1E-262, OBD Careful visual check is required for some symptom pro-
system check, List of Function Checks and check all cedures. By this check, the problem can be corrected
the following items. without performing further check, and time can be
Fuel consumption varies depending on handling of saved. This check includes the following items.
each machine. Check the machine manufacturers Wire is connected properly, tightened securely or
measure of fuel consumption (A). Measure of fuel not cut.
consumption (L {qts}/hour) ECM ground is not contaminated and installed to
Check the actual fuel consumption (B). Actual fuel the proper position securely.
consumption (L {qts}/hour) Pipes and hoses relevant to fuel, air and oil are
If B is bigger than A, check the machines setting free of crack or twist, and are properly connected.
by referring to the machines manual. Thoroughly check for any oil leakage and clogging.
Check if excessive load is applied to the machine. Fuel system is free from oil leakage, and pipe is
Refer to the list of inspection and maintenance not damaged or dent.
items of the operation manual for proper inspection Intake system parts for fault.
depending on the operation time. Exhaust system parts for fault.
If the operation time exceeds 3000 hours, inspect
by referring to the machines manual. Diagnostic aid
ECM and diagnosis lamp operate properly. Fuel system fault (run out of fuel, frozen fuel, air
Check the DTC. mixed in fuel pipe, faulty filter [clog in main filter,
Check the condition of the machine to identify the gauze filter], pipe fault, fuel quality, fuel tank [for-
applicable symptom from List of trouble symp- eign matter, fuel suction fault])
tom. Perform the procedure described in the Intake system fault (EGR valve fault)
symptom chart. Injector fault (excessive fuel injection etc.)
Check with the customer if correct engine oil and Engine body fault (seizure, compression pressure
fuel are used. shortage, other mechanical trouble)
Check if periodic maintenance has been per- Machine side related equipment trouble (oil pres-
formed for engine oil replacement, air cleaner filter, sure pump etc.)
fuel filter, etc.
ECM trouble (body, power supply, ground, etc.)
the harness for loosened wire causing short circuit
Repair if faulty.

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 machines set-

ting or if excessive load is applied to the
machine by referring to the machines 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 Go to 1E-288,
accumulation. Intake system
4
Is the procedure completed? Go to Step 5. tion Checks.
Check the exhaust system for crush, bent or clog- Go to 1E-288,
ging. Exhaust system
5
Is the procedure completed? Go to Step 6. tion Checks.
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.
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.


Inspection location of engine intake/exhaust system
4
5 6
TSJJ0126
Name
1. From intercooler 4. Exhaust pipe
2. EGR valve 5. To intercooler
3. EGR cooler 6. From air cleaner
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 1E-262, OBD Careful visual check is required for some symptom pro-
system check, List of Function Checks and check all cedures. By this check, the problem can be corrected
the following items. without performing further check, and time can be
Oil consumption varies depending on handling of saved. This check includes the following items.
each machine. Check the machine manufacturers If bluish-white smoke is emitted continuously while
measure of oil consumption (A). Measure of oil engine running.
consumption/hour. Measure of oil consumption for If blow-by gas is emitted.
engine alone: 4 L {4.2 qts}/ 100 hours
If oil is mixed in the coolant.
Check the actual oil consumption (B). Actual oil
Pipes and hoses relevant to oil are free of crack or
consumption /hour
twist, and are properly connected. Thoroughly
Refer to the list of inspection and maintenance check for any oil leakage and clogging.
items of the operation manual for proper inspection
Lubrication system is free from oil leakage, and
depending on the operation time.
pipe is not damaged or dent.
If the operation time exceeds 3000 hours, inspect
Intake system parts for fault (turbocharger check).
by referring to the machines manual.
ECM and diagnosis lamp operate properly. Diagnostic aid
Check the DTC.
Intake system fault (rise/decline of oil, excessive
Check the condition of the machine to identify the blow-by gas)
applicable symptom from the table of contents. Engine body fault (oil combustion, excessive blow-
Perform the procedure described in the symptom by gas)
chart. Also, perform the function diagnosis to check the oper-
Check with the customer if correct engine oil and ation and control of each part. Repair if faulty.
fuel are used.

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 machines manual.
Note:
Use the operation mode mentioned in the
machines 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 the specified value or more? 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.

Replace 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
5-8840-2691-0
Digital multimeter
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

TB290 Troubleshooting 4JJ1 de

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

TB290 Troubleshooting 4JJ1 de

Hochgeladen von

Copyright:

Verfügbare Formate

Introduction

This Troubleshooting Manual describes the structure and the troubleshooting of

Isuzu Motors Limited

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

Abbrevia- Name Meaning and remarks

Abbrevia- Name Meaning and remarks

List of parts according to engine control specifications

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

CKP sensor (MPU) A

1. Sections surrounded by long broken lines are used

5 The present trouble turns to history trouble when

EGR position sensor/EGR motor

Is the Common rail pressure sensor output volt-

Is the trouble detected? Go to Step 12. Go to Step 7.

2. If the trouble is detected, repair or replace as

Precautions on Service Work

Commercial electrical equipment CAUTION:

Procedure of Trouble Diagnosis

ECM Connector Data Link Connector

Data Link Connector

Injector ID Code Read DTC Snapshot 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 customers 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. Items 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, EMPSIII, KW display CAN display

Tech2, EMPSIII, KW display CAN display

List of items displayed on scan tool with CAN communication

Hitachi Construction Machinery Co., Ltd.

ECM Connector Data Link Connector

Data Link Connector