6WG1-E-01(1_2).pdf

Introduction
This Troubleshooting Manual describes the structure of electronic control fuel injection
system (common rail type) in 6WG1 industrial engine.
Use this manual sufficiently to perform service work properly and quickly.
Hitachi Construction Machinery Co.,Ltd

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

Disassemble and Assemble Engine
General Information
Engine Mechanical (6WG1(Common rail))
Cooling System (6WG1(Common rail))
Fuel System (6WG1(Common rail))
Electrical System (6WG1(Common rail))
Lubricating System (6WG1(Common rail))
Intake System (6WG1(Common rail))
Preheating System (6WG1(Common rail))
Electronic Control Fuel Injection System (Common Rail Type) 1E-1
Control System
Electronic Control Fuel Injection System (Common Rail Type)
Table of Contents
How to Use This Manual ....................................... 1E-4 How to Use Breaker Box ...................................1E-185
How to use this manual...................................... 1E-4 Breaker box inspection procedure .................1E-185
Table of abbreviation.......................................... 1E-5 Engine Control System .....................................1E-188
About colors of wirings ....................................... 1E-6 Description of function and operation for engine
About wiring diagrams........................................ 1E-7 control (common rail) system .........................1E-188
How to read trouble diagnosis section ............... 1E-8 Engine control module (ECM) ........................1E-196
Precautions on Service Work.............................. 1E-10 Engine component location diagram.............. 1E-198
Electrical system .............................................. 1E-10 Wiring diagram of engine control module (ECM)
Fuel injection system........................................ 1E-10 .......................................................................1E-208
Procedure of Trouble Diagnosis.......................... 1E-12 Pin arrangement of engine control module (ECM)
About trouble diagnosis.................................... 1E-12 .......................................................................1E-209
Trouble diagnostic procedure........................... 1E-13 Circuit diagram ...............................................1E-213
Interview........................................................... 1E-14 Engine harness location................................. 1E-226
Pre-inspection .................................................. 1E-16 Connector list .................................................1E-231
Trouble diagnosis............................................. 1E-16 List of Function Checks .....................................1E-234
How to read DTC ............................................. 1E-17 List of function checks....................................1E-234
Confirmation after repair .................................. 1E-19 OBD system check.........................................1E-235
List of final check items .................................... 1E-19 Diagnosis lamp illumination circuit system check
How to clear DTC............................................. 1E-20 .......................................................................1E-237
Trouble diagnosis with scan tool ...................... 1E-20 Diagnosis lamp blinking circuit system check 1E-239
How to Use Trouble Diagnosis-related Tool ....... 1E-25 Scan tool power supply circuit system check. 1E-243
Tech2 ............................................................... 1E-25 Scan tool communication circuit system check
Rewriting of Q adjust correction data by Tech2 .......................................................................1E-245
......................................................................... 1E-47 Starting circuit system check..........................1E-249
Injector ID code (No. 1 cylinder - No. 6 cylinder) Starting system check ....................................1E-255
registration setting using Tech2 ....................... 1E-54 Fuel system check .........................................1E-258
ID code upload (Tech2).................................... 1E-62 Intake system check.......................................1E-260
ID code download (ECM) ................................. 1E-67 Exhaust system check ...................................1E-261
TIS2000............................................................ 1E-72 EGR control system check.............................1E-262
How to Inspect Injector........................................ 1E-82 QOS system check ........................................ 1E-265
How to use injector checker ............................. 1E-82 List of Diagnostic Trouble Codes ......................1E-270
Method to identify using non-contact infrared List of diagnostic trouble codes for Hitachi
thermometer..................................................... 1E-86 Construction Machinery Co., Ltd....................1E-270
Injector balance test (Tech2)............................ 1E-87 DTC: P0088 (Flash code 118) Common rail pressure
Flash Tool (EMPS).............................................. 1E-88 is abnormally high (1st or 2nd stage) .............1E-283
Introduction ...................................................... 1E-88 DTC: P0089 (Flash code 151) Common rail pressure
Cautions ........................................................... 1E-88 fault (Excessive pressure feed in supply pump)
EMPS Component Parts .................................. 1E-90 .......................................................................1E-288
ECM (hardware) compatibility .......................... 1E-91 DTC: P0091 (Flash code 247) PCV circuit fault
System Requirements for EMPS Software (PCV1 open circuit or GND short circuit) ....... 1E-293
(Recommended) .............................................. 1E-91 DTC: P0092 (Flash code 217) PCV circuit fault
EMPS (software) Setup Procedure .................. 1E-92 (PCV1 +B short circuit)...................................1E-299
EMPS Operation Procedure................................ 1E-95 DTC: P0107 (Flash code 71) Barometric pressure
1. Preparation................................................... 1E-95 sensor circuit input is low (open circuit or ground
2. ECM Reflash ................................................ 1E-97 short) ..............................................................1E-304
3. Injector Replacement ................................. 1E-115 DTC: P0108 (Flash code 71) Barometric pressure
4. Replace ECM (Same Model) ..................... 1E-128 sensor circuit input is high (+5V short) ...........1E-311
5. Factory Setting ........................................... 1E-155 DTC: P0112 (Flash code 22) Intake air temperature
6. Recover Point............................................. 1E-166 sensor fault (low voltage fault, GND short, short
7. Error Messages.......................................... 1E-168 circuit).............................................................1E-317
8. Error Code List ........................................... 1E-175
1E-2 Electronic Control Fuel Injection System (Common Rail Type)
DTC: P0113 (Flash code 22) Intake air temperature DTC: P0606 (Flash code 51) CPU fault .........1E-477
sensor fault (high voltage fault, open circuit or short to DTC: P0606 (Flash code 52) CPU monitoring IC fault
power supply circuit) ...................................... 1E-323 .......................................................................1E-479
DTC: P0117 (Flash code 23) Engine coolant DTC: P0611 (Flash code 34) Charge circuit fault
temperature sensor fault (low voltage fault, GND (bank 1) ..........................................................1E-481
short, short circuit).......................................... 1E-331 DTC: P0612 (Flash code 34) Charge circuit fault
DTC: P0118 (Flash code 23) Engine coolant (bank 2) ..........................................................1E-484
temperature sensor input is high (open circuit or short DTC: P0615 (Flash code 19) Starter cut relay circuit
to power supply)............................................. 1E-337 fault ................................................................1E-487
DTC: P0182 (Flash code 211) Fuel temperature DTC: P0650 (Flash code 77) Diagnosis lamp circuit
sensor fault (low voltage fault, GND short) .... 1E-344 fault ................................................................1E-493
DTC: P0183 (Flash code 211) Fuel temperature DTC: P1093 (Flash code 227) No pump pressure
sensor fault (high voltage fault, open circuit or short to feed (2nd stage) .............................................1E-499
power supply circuit) ...................................... 1E-350 DTC: P1094 (Flash code 226) No pump pressure
DTC: P0192 (Flash code 245) Common rail pressure feed (1st stage) ..............................................1E-507
sensor fault (low voltage fault, short circuit) ... 1E-358 DTC: P1095 (Flash code 225) Pressure limiter open
DTC: P0193 (Flash code 245) Common rail pressure .......................................................................1E-515
sensor fault (high voltage fault) ...................... 1E-364 DTC: P1112 (Flash code 295) Boost temperature
DTC: P0201 (Flash code 271) Open circuit in sensor fault (low voltage fault, ground short) .1E-524
injection nozzle #1 drive system .................... 1E-370 DTC: P1113 (Flash code 295) Boost temperature
DTC: P0202 (Flash code 272) Open circuit in sensor fault (high voltage fault, open circuit, short to
injection nozzle #2 drive system .................... 1E-375 power supply circuit) ......................................1E-531
DTC: P0203 (Flash code 273) Open circuit in DTC: P1173 (Flash code 542) Overheat........1E-538
injection nozzle #3 drive system .................... 1E-380 DTC: P1225 (Flash code 31) Idle UP/DOWN switch
DTC: P0204 (Flash code 274) Open circuit in fault ................................................................1E-543
injection nozzle #4 drive system .................... 1E-385 DTC: P1261 (Flash code 158) Injection nozzle
DTC: P0205 (Flash code 275) Open circuit in common 1 drive system fault .........................1E-547
injection nozzle #5 drive system .................... 1E-390 DTC: P1262 (Flash code 159) Injection nozzle
DTC: P0206 (Flash code 276) Open circuit in common 2 drive system fault .........................1E-556
injection nozzle #6 drive system .................... 1E-395 DTC: P1271 (Flash code 24) Accelerator sensor 1-2
DTC: P0219 (Flash code 543) Overrun ......... 1E-400 comparison fault.............................................1E-565
DTC: P0237 (Flash code 32) Boost sensor pressure DTC: P1277 (Flash code 24) Accelerator sensor 1
fault (low voltage fault, open circuit)............... 1E-402 fault (low voltage fault) ...................................1E-571
DTC: P0238 (Flash code 32) Boost pressure sensor DTC: P1278 (Flash code 24) Accelerator sensor 1
fault (high voltage fault, short to power supply circuit, fault (high voltage fault) ..................................1E-577
ground open circuit) ....................................... 1E-409 DTC: P1282 (Flash code 24) Accelerator sensor 2
DTC: P0335 (Flash code 15) Crank sensor fault (no fault (low voltage fault) ...................................1E-582
signal)............................................................. 1E-416 DTC: P1283 (Flash code 24) Accelerator sensor 2
DTC: P0336 (Flash code 15) Crank sensor fault fault (high voltage fault) ..................................1E-588
(signal fault).................................................... 1E-422 DTC: P1291 (Flash code 248) PCV circuit fault
DTC: P0340 (Flash code 14) G sensor fault (no (PCV2 open circuit or GND short circuit) .......1E-593
signal)............................................................. 1E-427 DTC: P1292 (Flash code 218) PCV circuit fault
DTC: P0341 (Flash code 14) G sensor fault (signal (PCV2 +B short circuit)...................................1E-599
fault) ............................................................... 1E-433 DTC: P1345 (Flash code 16) Cam sensor out of
DTC: P0380 (Flash code 66) Glow relay circuit fault phase .............................................................1E-604
....................................................................... 1E-438 DTC: P1625 (Flash code 416) Main relay fault
DTC: P0381 (Flash code 67) Glow plug lamp circuit .......................................................................1E-609
fault ................................................................ 1E-443 DTC: P1630 (Flash code 36) A/D conversion fault
DTC: P0487 (Flash code 44) EGR position sensor .......................................................................1E-616
fault ................................................................ 1E-449 DTC: P1631 (Flash code 55) Voltage fault in 5-V
DTC: P0488 (Flash code 45) EGR valve control fault power supply 1 ...............................................1E-618
....................................................................... 1E-454 DTC: P1632 (Flash code 55) Voltage fault in 5-V
DTC: P0522 (Flash code 294) Engine oil pressure power supply 2 ...............................................1E-622
sensor fault (low voltage fault, open circuit, ground DTC: P1633 (Flash code 55) Voltage fault in 5-V
short) .............................................................. 1E-460 power supply 3 ...............................................1E-626
DTC: P0523 (Flash code 295) Engine oil pressure DTC: P1634 (Flash code 55) Voltage fault in 5-V
sensor fault (high voltage fault, short to power supply, power supply 4 ...............................................1E-630
ground short).................................................. 1E-466 DTC: P1635 (Flash code 55) Voltage fault in 5-V
DTC: P0601 (Flash code 53) ROM fault ........ 1E-473 power supply 5 ...............................................1E-634
DTC: P0603 (Flash code 54) EEPROM fault . 1E-475 DTC: U2104 (Flash code 84) CAN Bus fault..1E-638
DTC: U2106 (Flash code 85) CAN timeout fault
....................................................................... 1E-643
List of Trouble Symptom ................................... 1E-648
List of trouble symptom .................................. 1E-648
Engine start failure ......................................... 1E-649
Engine stall..................................................... 1E-652
Engine hunting, rough idling........................... 1E-655
Engine output shortage .................................. 1E-659
Exhaust gas contains a lot of white smoke. ... 1E-663
Exhaust gas contains a lot of black smoke. ... 1E-666
Noise .............................................................. 1E-668
Fuel consumption deteriorates....................... 1E-670
Oil consumption deteriorates. ........................ 1E-673
Special Tool ...................................................... 1E-675
List of Special Tool......................................... 1E-675
Difference by Each Machine Manufacturer ....... 1E-676
Hitachi Construction Machinery Co., Ltd........ 1E-676
How to Use This Manual

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

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

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

Table of abbreviation
Abbreviation Name Meaning and remarks

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

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

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

sensor signal SV SV sensor signal
SV
CKP CKP Engine coolant

Fuel temperature Vcc
HIGH LOW temperature
signal signal sensor signal
sensor signal
108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
3 H-6 7 H-20 11 H-20 10 H-20 9 H-20

4
0.75 0.75 0.75

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

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

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

The following guidelines should be followed to pre-
Commercial electrical equipment means that commer-
vent the damage caused by electrostatic dis-
cial electrical components installed to a machine after
charge:
shipment from factory. Be careful that no special con-
sideration for this equipment is taken in the design pro- • Do not touch the ECM connector pins or the
cess of the machine. electronic components soldered on to the cir-
cuit board of the ECM.
Caution: • Package of that part should not be opened until
Connect commercial electrical equipment to the the preparation of the installation of the
circuit whose power supply and ground wires are replacement part is completed.
not related to the electronic control system. • Connect that package to the normal grounding
on the machine before taking out the parts
Commercial electrical equipment may cause malfunc-
from the package.
tion of the electronic control system even if they are
installed properly. They include devices which are not • If handling the parts with moving seats in slid-
connected to the electrical systems on the machine, ing, or sitting down from the standing position,
such as mobile phones or radios. Therefore, in trouble or walking for a certain distance, it is required
diagnosis of powertrain, first check if this commercial to touch the normal grounding before the
electrical equipment is installed, and if so, remove it installation of the parts.
from the machine. If the trouble has not been solved
after the removal, diagnose it in usual procedures.
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.
Damage caused by electrostatic discharge 3 2 1
The electronic components used in the electronic con-

trol systems are easy to get damaged, caused by elec-
trostatic discharge because they are designed to
operate in a very low voltage. Some kinds of electronic
components may get damaged by electrostatic in even
less than 100 V which human cannot feel. For refer-
ence sake, the voltage of 4,000 V is needed for human
to feel the flow of electrostatic discharge.
There are several ways for human body to have elec-
trostatic charged. The common way to be charged is 5
caused by friction or induction.
• For example, a charging by friction is caused when 4
a person slides on the seat of the machine. TSWG0167
Name
1. Injector pipe
2. Flow damper
3. Common rail
4. Common rail pressure sensor
5. Pressure limiter
• Do not reuse the high-pressure pipe and injector
pipe of the fuel system. Replace with new one if it
is removed.
• Never replace the pressure limiter or flow damper
alone. If faulty, replace the common rail assembly
and all the fuel pipes.
Procedure of Trouble Diagnosis

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

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

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

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

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

DTC: P0193 (Flush code 245) . . . . . . . . . . 10D-188 DTC: U2106 (Flush code 85). . . . . . . . . . . . 10D-393
DTC: P0201 (Flush code 271) . . . . . . . . . . 10D-193 List of trouble symptom . . . . . . . . . . . . . . . . . 10D-397
DTC: P0202 (Flush code 272) . . . . . . . . . . 10D-198 Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . 10D-401
DTC: P0203 (Flush code 273) . . . . . . . . . . 10D-203 Engine hunting, rough idling . . . . . . . . . . . . 10D-404
• The fault occurs for a short period and singly,

DTC: P0204 (Flush code 274) . . . . . . . . . . 10D-208 Engine output shortage . . . . . . . . . . . . . . . . 10D-408
DTC: P0205 (Flush code 275) . . . . . . . . . . 10D-213 Exhaust gas contains a lot of white smoke.. 10D-411
DTC: P0206 (Flush code 276) . . . . . . . . . . 10D-218 Exhaust gas contains a lot of black smoke.. 10D-414
DTC: P0219 (Flush code 543) . . . . . . . . . . 10D-223 Programming . . . . . . . . . . . . . . . . . . . . . . . . . 10D-416
but repeats intermittently and definitely occurs

DTC: P0237 (Flush code 32) . . . . . . . . . . . 10D-225 Rewriting of ECM (On-board)
TSWG0156
Name under a specific condition. A customer’s com-

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

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

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

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

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

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

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

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

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

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

faults are found in these items, inform a customer of If confirming repair using on-board diagnosis sys-
the following check items as required. tem check, perform the following steps. If not fol-
• An antenna should be installed as far away as pos- lowing these steps, unnecessary repair may be
sible from the electrical systems on the machine needed.
such as control unit/sensors. • Review and record the scan tool data related to
• Antenna cords should be installed at least 20 cm DTC which is diagnosed.
(7.8 in) away from the electrical systems on the • Clear the DTC.
machine such as control units/sensors. • Operate the machine while checking the rele-
• Do not put the antenna cords and other wire vant scan tool data.
together. Keep the antenna cords as far away from
other wire as possible.
• When installing an additional equipment, follow its
installation manual to install it securely.
• Do not install mobile communication equipment
with high output.
How to clear DTC Clear with ECM (intermittent trouble)
Clear of DTC The DTC stored in ECM will be cleared if the same one
is not valid within 20 ignition cycles.
The DTC, which have been stored in the engine control
module (ECM) upon trouble occurrence, will not be
erased even if the faulty parts are repaired, unless it is Trouble diagnosis with scan tool
compulsory cleared in the following procedure.
About scan tool
Clear with a scan tool There are scan tools for Hitachi Construction
If a scan tool (Tech2 or scan tool with KW communica- Machinery and the scan tool (Tech2) for Isuzu, and
tion) has been connected, it can be cleared by clear they have different display method respectively.
operation of the scan tool (Tech2 or scan tool with KW The scan tools for Hitachi Construction Machinery with
communication). CAN communication display only the physical value in
If a scan tool with CAN communication has been con- data parameters.
nected, clear with the memory clear switch.
Clear with memory clear switch

1. Turn the key switch to ON.
2. Turn the diagnosis switch to ON.
3. Turn the memory clear switch to ON.
4. Leave as it is ON for 3 seconds.
5. Turn the memory clear switch to OFF.
6. Turn the diagnosis switch to OFF.
7. Turn the key switch to OFF.
8. Leave as it is for 10 seconds.
10. Turn the diagnosis switch to ON.
11. Make sure that memory is cleared.
TSWG0185
Isuzu scan tool (Tech2) and the scan tools with KW

communication can display both the physical value and
voltage value.
In some diagnostic charts, both the voltage value and
physical value may be shown. Refer to the voltage
value for Tech2 and the scan tools with KW communi-
1 2 3 4 5 6 7 8 cation or the physical value for the scan tools with CAN
9 10 11 12 13 14 15 16 communication.
TSWG0023
Note:
• Refer to the machine’s manual for the locations of
memory clear switch and diagnosis switch.
• Perform the same procedure to clear memory
regardless of forms of switches (switches, connec-
tors). (ON = Connection, OFF = Disconnection)
Value
TSWG0182
Name
1. Tech2 and scan tool with KW communication
2. Scan tool with CAN communication
About scan tool display

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

Differential EGR Valve Position Sensor —
Engine Speed Act. Engine Speed
Desired Engine Speed Request Engine Speed
Intake Air Temperature Intake Air Temperature
— Boost pressure
— Boost Temperature
Engine Coolant Temperature Coolant Temperature
Fuel Temperature Fuel Temperature
Barometric Pressure Barometric Pressure
Engine oil pressure Engine Oil Pressure
— Fuel Flow
— Engine Torque
— Trip used fuel
— Total used fuel
Differential EGR Position (BLDC Motor) —
PCV Duty —
EGR BLDC Motor Duty —
EGR DC Motor Duty —
PCV F/B —
Desired Idle Speed —
Common Rail Pressure F/B Mode —
Engine Mode —
Target Fuel Flow —
Main Fuel Injection Timing —
Pre-fuel Injection Amount —
Main Fuel Injection Amount —
About scan tool (Tech2)

This is an useful tool to diagnose the electric faults and
the system check of the engine control system. The
Tech2 is small and light tester. It can communicate with
each control unit to perform various types of diagnosis
and test by connecting it to DLC equipped to the
machine using Tech2 adapter.
ECM control
DTC
Sensor output
Data Link Connector
Read DTC Actuator Test
V
V
RPM
RPM
Snapshot V
V
%
TSWG0121
Function of Tech2
Data display
This displays conditions recognized and controlled by
ECM at each items.
The values of display items is described in typical data V
of Tech2 data list. V
The contents of display items describe about data. RPM
RPM
V
V
%
MPa
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.
• The trigger type allows to record the data of the
time when DTC is displayed.
• The stored data can be replayed with a domestic
power supply.
Programming
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
Perform each test to check the operation or function of
appropriate parts for faults.
When giving instruction to ECM from test screen, set
the select switch of the Tech2 adapter to “2” position.
Caution:
Each test may not performed if the machine, engine
operation status, coolant temperature, vehicle
speed, switch status, gear position, etc. does not
meet conditions or if DTC is detected.
How to Use Trouble Diagnosis-related Tool

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

While operating the Tech2, selection boxes appear on They are used to select the menu or switch the display
the upper part of the screen. The softkeys correspond on the screen of Tech2. Selected part is highlighted in
the selection boxes. They cannot be used unless the the screen.
selection boxes are displayed.
Action keys (YES, NO, ENTER, EXIT)
They are used to execute the operation of Tech2,
respond to instruction/question, and switch/move to
each menu screen.
Function keys (F0 — F9) Precautions on handling Tech2
They are used to execute a menu function in the
Ventilation
screen. These keys also correspond to F numbers,
such as “F0”, when they are displayed on the menu If performing inspection and test with engine running in
screen. badly ventilated area, such as garage, ventilate suffi-
ciently. In badly ventilated area, poisoning may occur
Help key (?) due to inhaling colorless, odorless carbon monoxide
Explanation of Tech2 function, which is being used at included exhaust gas.
the time when the key is pressed, is displayed
Control keys (PWR / SHIFT) Handling
The PWR key turns on/off the power to the Tech2. The • The Tech2 is “precision electronic device”. Handle
SHIFT key is used to adjust the screen contract. When with extreme care.
the SHIFT key is active, the orange LED illuminates. In • Operating voltage of Tech2 is DC 12 V. Do not
this case, all the keys except selection keys and func- energize 24 V to it.
tions are locked. When the power is on, the green LED
illuminates.
Wide stand
Use this as a stand. The stand opens angle of 0 —
180°.
Display area (LCD)
This is liquid crystal display (LCD) with contrast adjust-
ing function. It displays ECM information and various
instructions.
Machine communication interface (VCI) module
This is a module to communicate between the machine
and Tech2.
Fastening bar of VCI module
The bar is used to install/fasten/remove the VCI.
Connector of DLC cable connection
This is used to connect the Tech2 to the machine. Con-
nect the DLC cable. TSWG0111
• Do not have an impact on it by dropping. It causes

Connector for AC adapter connection internal faults even no damage on appearance.
This is used to connect the attached AC adapter when
using Tech2 with other than the machine.
PCMCIA card insertion slot with cover
Open the cover when inserting the PCMCIA card into
Tech2. Insert the PCMCIA card with the cover opened.
Never insert/remove the PCMCIA card when the Tech2
is powered on.
PCMCIA card release button
This is used to remove the PCMCIA card from Tech2.
Press the button to remove the PCMCIA card. Never
remove the PCMCIA card when the Tech2 is powered
on.
Connector for external communication (RS-232
port)
This is used to connect the Tech2 to a computer.
Connector for external communication (RS-485
port) TSWG0112
This is a connector for phone line connection, however • Be sure to turn off the power of Tech2 when install-
it is not currently used. Do not connect the phone line ing/removing the PCMCIA card. Avoid repetition of
etc. to this connector. installing/removing the card as possible. Other-
wise, the card may be deteriorated.
• Before turning on the Tech2, make sure that the
cables and adapters are connected securely.
• Do not disconnect the cables and adapters con-
nected to Tech2 while the key switch is ON or the
engine is starting.
• Do not connect the phone jack to communication
port on the side of Tech2.
TSWG0115
• Avoid using and storing it in a place with extreme

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

following screen.
TSWG0124
1. Denotes recognition of DTC.

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

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

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

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

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

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

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

mal.
EGR regulating valve test

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

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

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

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

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

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

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

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

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

• To go to Step15-5, modify the Q adjust data within • When the writing of data completes, the following
the set value and press the softkey “Program”. screen will appear.
This indicates that the result of comparison of
entered data with that written in the EEPROM of
the ECM is in good condition.
TSHK0102
Step 15-5
• If the entered values meet the conditions in Step TSHK0104
15-1 and 15-3, the status display of data registra-

tion (writing) from the Tech2 to ECM as shown Step 16-1
below will appear. • If the entered Q adjust data in Step 15-1 does not
correspond to that written in the EEPROM of the
ECM, the following message will appear.
Pressing the softkey [End] returns you to Step 11.
Injector ID code (No. 1 cylinder - No. 6
cylinder) registration setting using Tech2
Preparation
If you plan to reflash the ECM part number at the QR
code registration setting, reflash first.
If you reflash after the registration, the QR code cannot
be correctly registered in ECM.
“Q adjust, Injector code label” is attached to the cylin-
der head cover. It is used for rewriting and registering
the ID.
1 2 3 4
TSHK0105
TSHK0098
Name
1. Engine number
2. Typical engine model
3. Q adjust information
4. Injector information
There is the injector code on the top of injector as well.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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


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

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

ECM POWER switch: OFF

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


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

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

button.
After configuring the power switch setting, click the

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

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

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

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

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

Procedure” screen.

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

screen shown below.
Battery Connection

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

3.2.1 User Authentication Screen (Normal)

[Cancel] button.

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

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

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

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

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

power supply.


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

If the upload is successful, advance to “3.8 Change

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


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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

below.

screen shown below.
Battery Connection 4.2 User Authentication Screen

[Cancel] button.

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

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

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

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

WindowsXP
Windows2000
[Next] button.

Selection Menu.”
ton.
button.

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

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

power supply.

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

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

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

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

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

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


button.
After configuring the power switch setting, clicking the

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

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

below.

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

advance to next.
For [Compulsory Reflash]

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

Battery Connection
4.13 Connection Confirmation Screen

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

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

“4.15 Selection Menu.”
ton.
button.

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

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

power supply.

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

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



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

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

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

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

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


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

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


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


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

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

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

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

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

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

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


button.

4.36 Memory Clear

dure.

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

to advance to the next Connection Procedure screen.

below.

screen shown below.
Battery Connection 5.2 User Authentication Screen

[Cancel] button.

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

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

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

nected.

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

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

power supply.


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


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

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

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


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

ECM POWER switch: OFF Battery Connection

button.

5.14 Memory Clear

dure.

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

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

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

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

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

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

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

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

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

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

selected

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

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

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

cation error properly.
Last process Last process continu-

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

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

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

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

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

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

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

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

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

selected.
ENGINE NUMBER is Enter the ENGINE NUMBER.

not input.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

CAN communication Machine control unit
Basic fuel injection amount

Boost pressure sensor input
CKP sensor input
G 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
PCV opening
time determination Injector coil energizing time
Timing determination
Common rail pressure sensor
Common rail
Injector coil
PCV
Injector
Supply pump
Fuel tank
TSWG0003
About fuel injection correction
ECM calculates the basic injection amount based on
the signals from accelerator position sensor, boost
pressure sensor, CKP sensor, G sensor, etc. It regu-
lates the opening/closing period of PCV or electric con-
duction of injector according to the common rail
pressure, engine coolant temperature, etc. at this time,
Fuel flow limit (mm 3/st)

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

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

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

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

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

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

PCV (Pressure control valve)
TWV (Injector) 1 - 6
Sensor input
Crankshaft position sensor
G sensor
Engine coolant temperature sensor
Barometric pressure sensor
Common rail pressure sensor Actuator control output
Boost pressure sensor EGR DC motor
Accelerator position sensor 1, 2
Vehicle speed sensor
Oil pressure sensor
Boost temperature sensor
Intake air temperature sensor
ECM Relay, lamp control output
Glow relay
Starter cut relay
Diagnosis lamp
QOS indicator lamp
Switch input
Oil pressure lamp
Key switch (ON/Start)
Boost pressure lamp
Diagnostic switch
Idling control selector switch
Idling control switch (UP/DOWN)
EGR position sensor
Mode map switch 1, 2, 3
Memory clear switch Communication
Engine stop switch Speed signal (output to tachometer)
Starter relay Tech 2 signal
CAN (ECU on machine side)
TSWG0001
Electronic control fuel injection system (Common Injection pressure control

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

pressure sensor Common rail limiter
Fuel Fuel Flow damper

filter filter
Supply pump
Injector
Fuel tank ECM
Each sensor
Accelerator, Boost pressure,
Engine coolant temperature, etc.
CKP sensor
TSWG0142
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 pressure control
valve (PCV) by the signal from ECM to control fuel
amount supplied to common rail.
TSWG0143
Name
1. Common rail 5. Pre-filter
2. Fuel filter 6. Feed pump
3. Injector 7. Supply pump
4. Fuel tank
EGR (Exhaust gas recirculation) EGR control

Exhaust Gas Recirculation system is abbreviated to ECM operates the motor according to engine speed,
EGR system. It recirculates part of exhaust gas into engine load, etc. to control amount of EGR valve lift.
intake manifold to mix an inert gas with intake air. This Amount of valve lift is detected by EGR position sensor.
leads to lower the combustion temperature to limit The dark color area in the figure shows that the valve
emissions of nitrogen oxide (NOx). lift amount is large, and the darkest color area shows
It controls amount of EGR by opening/closing the EGR that the valve lift amount is almost 100%.
valve installed between exhaust manifold and intake
manifold. It determines amount of EGR, based on the
engine speed and load rate on engine (fuel injection
amount), and operates the EGR valve to control the
amount of EGR.
The cooling system (EGR cooler) equipped on the
EGR gas passage allows to cool down high tempera-
ture EGR gas and mix it with new air to lower the com-
bustion temperature further, resulting in limiting NOx
effectively (Cooled EGR).
On 6WG1-TC machine, the EGR system has the check
valve to stop backward flow of EGR gas and flows it in
one way direction, leading to increase the amount of
EGR.
Accelerator position
No idle EGR
Engine speed
TSWG0174
EGR system schematic diagram
Outlet port of coolant Inlet port of coolant

EGR cooler
EGR valve
EGR valve position sensor

Exhaust

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

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

matching box
Engine speed signal

Vehicle speed sensor
Check for speed limit control

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

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

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

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

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

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

cuits should not be overloaded. In case of testing of 10 sec
open and short circuits, the circuits of the ECM must

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

The power supply inside the ECM does not go off for
about 10 seconds after turning the key switch OFF. If
the ECM power needs to be off such as for memory
clear, wait for more than 10 seconds after turning the
key switch OFF.
Engine component location diagram
(Component location, its form and parts to be used vary depending on each machine.)
7 4 8
1 (#2)
5
1 (#1)
6 9
11
2 10
TSWG0024
Name
1. Pressure control valve (PCV #1, PCV #2) 7. EGR valve
2. Fuel temperature (FT) sensor 8. Boost pressure sensor
3. G sensor 9. CKP sensor
4. Boost temperature sensor 10. Engine oil pressure sensor
5. Common rail pressure sensor 11. Overheating switch
6. Engine coolant temperature (ECT) sensor
Supply pump Name

1. PCV #1
2. PCV #2
3. G sensor
1 2 4. Feed pump
5. Fuel temperature (FT) sensor
5
The supply pump pressurizes fuel using engine output,
and pressure-feeds fuel to common rail. Supply pump
has also PCV (pressure control valve), fuel tempera-
ture (FT) sensor and feed pump.
Note:
3 For work procedure, refer to “Engine section” in the ser-
vice manual.
TSWG0009
PCV (Pressure control valve) Fuel temperature (FT) sensor
1 2
TSWG0010 TSWG0011
Name
1. PCV #1 The fuel temperature (FT) sensor is installed onto the
2. PCV #2 supply pump, and the thermistor changes the resis-
tance according to the temperature. The resistance is
low when the fuel temperature is high, and is high when
The PCV (pressure control valve) is installed onto sup- the temperature is low. The engine control module
ply pump section and controls pressure feed of fuel (ECM) energizes the voltage (5 V) to the FT sensor
(discharge amount) to common rail. The engine control through pull up resistance, and calculates fuel tempera-
module (ECM) regulates period of electric conduction ture based on change of voltage to use for various con-
of PCV to regulate the fuel discharge amount. trols such as supply pump control etc. If the resistance
is low (temperature is high), the voltage becomes low; if
Removal the resistance is high (temperature is low), the voltage
• Do not replace the PCV. becomes high.
• If it is faulty, replace it as supply pump ASM.
Removal
• Disconnect the connector and remove it with
19mm-wrench
19mm
TSWG0194
TSWG0189
G sensor Common rail
1 2
TSWG0018 TSWG0012
Name
The G sensor is installed onto supply pump and pro- 1. Common rail
duces the CMP signal when the cam portion of cam- 2. Common rail pressure sensor
shaft passes the sensor. The engine control module 3. Pressure limiter
(ECM) distinguishes the cylinders by the G signal input 4. Flow damper
from G sensor, determines the crank angle and uses it
to control fuel injection and calculate the engine speed.
These controls are performed, usually based on CKP The common rail receives fuel from supply pump, holds
signal. However it is done, based on G signal if the the common rail (fuel) pressure and distributes fuel to
CKP sensor is faulty. each cylinder. The common rail has common rail pres-
sure sensor, flow damper and pressure limiter.
Removal
Note:
• Do not replace the G sensor.
For work procedure, refer to “Engine section” in the ser-
• If it is faulty, replace it as supply pump ASM. vice manual.
TSWG0195
Flow damper Pressure limiter
4 4
3 3
1 2 1 2
TSWG0012 TSWG0012
Name Name
1. Common rail 1. Common rail
2. Common rail pressure sensor 2. Common rail pressure sensor
3. Pressure limiter 3. Pressure limiter
4. Flow damper 4. Flow damper
The flow damper is installed onto outlet port to each The pressure limiter operates to release the pressure in
injector of common rail, limits pressure pulsation in common rail when the pressure becomes extremely
common rail and prevents over-injected fuel from injec- high.
tor. When the flow damper operates, fuel supply to
injector is stopped. Removal
• Do not replace the pressure limiter.
Removal
• If it is damaged, replace it as common rail ASM.
• Do not replace the flow damper.
Common rail pressure sensor Injector
1 2
TSWG0012 TSWG0016
Name
1. Common rail The injector is installed onto cylinder head section and
2. Common rail pressure sensor is controlled by engine control module (ECM) to inject
3. Pressure limiter fuel. The ECM raises the voltage for operating injectors
4. Flow damper internally, energizes to injector, and regulates period of
electric conduction of injector to control fuel injection
amount and injection timing.
The common rail pressure sensor is installed onto com-
mon rail, detects fuel pressure in common rail, converts Note:
the pressure into the voltage signal and sends it to For work procedure, refer to “Engine section” in the ser-
engine control module (ECM). Voltage becomes higher vice manual.
as pressure becomes higher, and lower as one does
lower. ECM calculates the actual common rail pressure Engine coolant temperature (ECT) sensor
(fuel pressure) based on the voltage signal sent from
sensors and uses it for fuel injection control etc.
Removal
• Do not replace the common rail pressure sensor.
TSWG0017
TSWG0190
The engine coolant temperature (ECT) sensor is Crankshaft position (CKP) sensor
installed onto engine block, and the thermistor changes
the resistance according to the temperature. Resis-
tance is low at high engine coolant temperature and
high at low engine coolant temperature. The engine
control module (ECM) energizes the voltage (5 V) to
the ECT sensor through pull up resistance, and calcu-
lates engine coolant temperature based on change of
voltage to use for various controls such as fuel injection
etc. If the resistance is low (temperature is high), the
voltage becomes low; if the resistance is high (temper-
ature is low), the voltage becomes high.
Removal
• Disconnect the connector and remove it with
19mm-wrench
TSWG0019
The crankshaft position (CKP) sensor is installed onto

flywheel housing and produces the CKP signal when
the convex portion of flywheel passes the sensor. The
engine control module (ECM) distinguishes the cylin-
ders by the G signal input from G sensor, determines
19mm
the crank angle and uses it to control fuel injection and
calculate the engine speed. These controls are per-
formed, usually based on CKP signal. However it is
done, based on G signal if the CKP sensor is faulty.
Removal
• Disconnect the connector, and remove the 10mm-
mounting bolt and sensor.
TSWG0186
Installation
• Apply Loctite 572 before installing it.
Tightening torque:
19.6 — 29.4 N⋅m {2 — 3kg⋅m/14 — 22 lb⋅ft}
10mm
TSHK0123
Installation
Tightening torque:
14.7 — 24.5 N⋅m {1.5 — 2.5 kg⋅m/11 — 18 lb⋅ft}
Engine oil pressure sensor Accelerator position (AP) 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 machine’s manual for the location of accel-
erator position sensor.
Barometric pressure sensor
TSWG0067
The engine oil pressure sensor is installed near the

starter motor of the cylinder block; it detects engine oil
pressure, 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.
Removal
• Disconnect the connector, and remove the 27 mm-
mounting bolt and sensor. (Lock position of the
connector is the lower side)
TSWG0020
The barometric pressure sensor is installed onto the

machine side and converts the barometric pressure
into voltage signal. The ECM calculates barometric
pressure by voltage signal and performs fuel injection
amount correction (high-altitude correction) etc. by
barometric pressure.
Note:
Refer to the machine’s manual for the location of baro-
metric pressure sensor.
TSWG0192
Installation
Tightening torque:
41 N⋅m {4.2 kg⋅m/30 lb⋅ft}
Intake air temperature (IAT) sensor Removal
• Disconnect the connector, and remove the six 12
mm-mounting bolts and EGR valve.
The intake air temperature (IAT) sensor is installed TSWG0193

onto the machine side and detects the temperature of
intake air for optimum fuel injection control.
Tightening torque:
10.8 — 16.3 N⋅m {1.1 — 1.7 kg⋅m/96 — 144 lb⋅in}
Note:
Refer to the machine’s manual for the location of intake
air temperature (IAT) sensor.
EGR position sensor
TSWG0196
TSWG0149
It is installed in EGR valve and detects the valve lift

amount of EGR.
Note:
Do not disassemble the EGR position sensor. If it is
faulty, replace it as EGR valve ASM.
Boost pressure sensor Boost temperature sensor
TSWG0022
The boost pressure sensor uses the pressure hose The boost temperature sensor is installed onto the
between the boost pressure sensor and intake pipe, EGR valve upstream side of intake manifold. The sen-
detects boost (intake air pressure), converts the pres- sor is thermistor type. The resistance in the sensor
sure into the voltage signal and sends it to engine con- changes as the temperature changes.
trol module (ECM). Voltage becomes higher as
pressure becomes higher, and lower as one does Removal
lower. ECM calculates the boost (intake air pressure) • Disconnect the connector and remove it with
based on the voltage signal sent from sensors and 19mm-wrench
uses it for fuel injection control etc.
Removal
• Disconnect the connector, and remove the two
10mm-mounting bolts, hoses and sensor.
10mm
19mm
TSWG0187
Installation
Tightening torque:
10.8 — 16.3 N⋅m {1.1 — 1.7 kg⋅m/96 — 144 lb⋅in}
TSWG0188
Diagnosis lamp
Installation
It indicates DTC by blinking after the diagnosis switch is
Tightening torque:
turned to ON.
4 — 6 N⋅m {0.4 — 0.6 kg⋅m/35 — 53 lb⋅in}
Note:
Refer to the machine’s manual for the locations of diag-
nosis lamp.
DLC (data link connector)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
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 machine’s 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 machine’s 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 (1, 2, 3)

The mode selector switch allows to operate at the
engine speed set by each mode.
Note:
mode selector switch.
Wiring diagram of engine control module (ECM)
(*: Refer to the machine’s manual for fuse capacity.)
(15A)*
24
107
Key switch (ON) Engine stop switch CKP sensor
(50A)*
47 106
Idling selector switch
29 108
Idle up switch
30
80
Idle down switch Engine oil
31 67
Mode map switch 0 79 pressure sensor
25
Mode map switch 1
34
Mode map switch 2 84
48 Engine coolant
Diagnostic lamp temperature sensor
6
Engine oil pressure lamp
17
QOS indicator lamp 83
11 Fuel temperature
Boost temperature lamp sensor
7
10
(60A)*
87
98 G sensor
Glow relay 101
100
82
(100A)*
Glow plug 90 Common rail

pressure sensor
(10A)*
46 94 U
EGR valve
Key switch (ST) 93 V
Battery position sensor
Starter relay 92 W
Starter cut relay Vehicle speed

19
Starter sensor
121
14
ECM
PCV 1 Injector #1
105 119
(15A)*
113
89 117 Injector #3
97
PCV 2
114 Injector #2
Main relay 5
(30A)*
2
116
40
21 Injector #5
120
42
Accelerator Injector #6
63 118
position
sensor 64
41 Injector #4
115
20
Barometric 61
pressure 71 8 Tachometer
sensor 60
Intake air 18
72
temperature 37
sensor
Boost
95 38 7 TOOL
pressure
91 52 1
sensor
109
4 Data link connector
Boost 74 5
temperature 81
sensor
43
62
U 111
EGR valve
motor V 103 1
M
W 110 3
4
Memory clear switch
32
TSWG0025
Pin arrangement of engine control module (ECM)
TSWG0026
81-pin connector
Pin No. Terminal name Connection

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

12 — —
13 — —
14 OS-STARTR Starter cut relay
15 — —
16 — —
17 OS-OILPL Engine oil pressure lamp
18 CC-CAN-H CAN-HIGH
19 IF-SPD Vehicle speed sensor signal
20 SG-SLD1 Accelerator position sensor 1 GND
21 OS-MAINR ECM main relay
22 — —
23 — —
24 IS-IGKEY Key switch ON signal
25 IS-MDMAP0 Mode selector switch MAP0
26 — —
27 — —
28 — —
29 IS-IDLMNL Idling control selector switch
30 IS-IDLUP Idling control switch-up signal
31 IS-IDLDWN Idling control switch-down signal
32 IS-MEMCL Memory clear switch
33 — —
35 — —
36 — —
37 CC-CAN-L CAN-LOW
38 CC-KW2000 Data link connector
39 — —
40 OS-MAINR ECM main relay
41 SG-5VRT1 Accelerator position (AP) sensor GND
42 SP-5V1 Accelerator position (AP) sensor power supply
43 PG-SIGN GND
44 — —
45 — —
46 IS-START Key switch start signal
47 ENGSTP Engine stop switch
49 — —
50 — —
51 — —
52 IS-DIAG Diagnostic switch

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

82 IA-PFUEL Common rail pressure sensor signal
83 IA-THL Fuel temperature sensor signal
84 IA-THW Engine coolant temperature sensor signal
85 — —
86 — —
87 SP-5V5 Common rail pressure sensor power supply
88 — —
89 OS-PCV2 PCV2 drive

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

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

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

plug
Starter cut relay signal

TSWG0028
Starter for safety relay, glow circuit
module (ECM)
Engine control
(ON) (ST)
Br C
Key switch
ACC
B
START
OFF
ON
A
(ON) (ST)
BBr C
Safety relay
START
OFF
ON
A
S
Glow relay
Starter
control
E-57
C
C
B
10
B
Glow
plug
Generator
B
Glow
relay
(100A)*
(60A)*
H-22
B/W
H-1
5
1
1
(15A)*
Battery
TSWG0068
CAN LOW CAN HIGH
Engine control
module (ECM)
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
CAN, GND, DLC circuits
6 FL-150 7 FL-150
DLC
Machine control unit

5 FL-150 4 FL-150
CAN HIGH CAN LOW

TSWG0029
(15A)*
A A
Machine trouble
diagnosis monitor
Diagnosis Engine oil QOS indicator Boost temperature Tachometer Meter

lamp pressure lamp lamp lamp
Indicator lamp, tachometer circuit
Machine
control unit
CAN LOW CAN HIGH
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 8 E-57
Diagnosis Engine oil pressure QOS indicator Boost temperature Engine control
lamp control lamp control lamp control lamp control module (ECM)
Tachometer signal
CAN HIGH CAN LOW
TSWG0030
Injector circuit
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
Injector Injector Injector Injector Injector Injector

(Cylinder No. 5) (Cylinder No. 6) (Cylinder No. 4) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 3)
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Cylinder No. 5 Cylinder No. 6 Cylinder No. 4 Cylinder No. 2 Cylinder No. 1 Cylinder No. 3
Feedback Feedback Feedback Feedback Feedback Feedback

B+ B+
TSWG0031
PCV circuit

Main relay
(15A)*
E-56
113
PCV1
E-161
E-161
H-6
E-56
5
0.75
R/W
H-6
105
2
1
2
0.75
R/L
PCV2
E-162
E-162
E-56
0.75
R/B
H-6
89
2
1
1
E-56
97
TSWG0032
Vehicle speed Engine oil pressure
sensor signal 5V 5V sensor signal
5V
CKP CKP Engine coolant

HIGH LOW Fuel temperature Vcc
temperature sensor
signal signal sensor signal signal
108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
3 H-6
7 H-20 11 H-20 10 H-20 9 H-20
engine oil pressure sensor circuit
3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 B
Pulse 0.75 0.75 0.75 0.75
matching Y/G B/Y R/B B/Y
0.5 0.5
V/W Y box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76
2 E-98 1 E-98
Engine
coolant
temperature
Fuel temperature sensor sensor
Engine oil
pressure sensor
CKP sensor A
3 E-90 Engine control

* CAN LOW CAN HIGH module (ECM)
0.75
R
4 H-6 37 E-57 18 E-57
Vehicle A
speed sensor
(*: Specifications vary depending on each machine. Refer to the machine’s manual.)
Meter
Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature
gauge
Machine trouble
diagnosis monitor
CKP sensor, vehicle speed sensor, fuel temperature sensor, engine coolant temperature sensor,
TSWG0033
Engine control
module (ECM)
5V Boost pressure
sensor signal
5V
Boost temperature
sensor signal
74 E-56 109 E-56 91 E-56 95 E-56
15 H-20 17 H-20 16 H-20 8 H-20

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

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

Boost pressure sensor
TSWG0034
G 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+
98 E-56 101 E-56 100 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56
3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

5 H-20 14 H-20 6 H-20 13 H-20 12 H-20
0.5 0.5
G sensor, common rail pressure sensor, EGR circuit
Br L/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75

0.5 L GY W/L G/W W/B G/B W/R L/W
L
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.5 0.5 0.5
B/W L/W Br L
1 E-112 2 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V

W U
EGR position sensor/EGR motor
EGR valve
G sensor Common rail pressure sensor
TSWG0035
A A
Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH Engine control
5V 5V module (ECM)
Vcc
37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57
Machine
control unit
CAN HIGH CAN LOW
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
TSWG0036
Key switch(ON)
(15A)*
Idling selector
Idle up Idle down Mode map Mode map Mode map
switch
switch switch switch 0 switch 1 switch 2
29 E-57 30 E-57 31 E-57 25 E-57 34 E-57 48 E-57

Idling selector switch, idle up switch, idle down switch, mode map switch circuit
Engine control
module (ECM)
Idling selector Idle up Idle down Mode map Mode map Mode map
switch signal switch signal switch signal switch 0 signal switch 1 signal switch 2 signal
TSWG0037
Memory clear switch, engine stop switch circuit
(15A)*
Key switch (ON)
control unit
Machine
E-57
CAN HIGH CAN LOW

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

A
E-57
47
Memory clear switch

A
E-57
32
B
B
TSWG0038
Engine harness location
:Engine harness
10 9 8 7
11 6
1 2
TSWG0040
Name
1. G sensor 7. Boost pressure sensor
2. Fuel temperature sensor 8. Boost temperature sensor
3. Engine oil pressure sensor 9. EGR position sensor
4. CKP sensor 10. PCV
5. Common rail pressure sensor 11. Glow plug
6. Engine coolant temperature sensor
82641-358
E75 E163 E80
1 2 3 4 EGR VALVE
SENSOR:BOOST PRESS SENSOR:BOOST TEMP 0.75 0.75 0.75 0.75
L G/Y G/W G/B
H1 5 6 7 8
1 2 0.75 0.75 0.75 0.75
1 GLOW PLUG 1 2 3 0.75 0.75 L/W W/L W/B W/R
5 0.75 0.75 0.75 R/ L B / R
B/W R/L L R/W
E90
SENSOR:WATER
H94
1 2 1 2 3 4 INJECTOR 1(CYL#1.2.3)
0.75 0.75 0.75 1.25 1.25
B/Y R /B L W W
3 5 6 7 8
0.75 INJECTOR
R 0.75 0.75
1 L /W G /R
H95
E162 INJECTOR 2(CYL#4.5.6)
1 2 PCV 2
0.75 0.75 1 2 3 4
R/ L R / B 0.75 1.25 1.25
G/B R R
5 6 7 8
INJECTOR 0.75 0.75
2 L/R L/Y
1 2 E98
0 .5 0 .5
PCV Rr
Y V /W
SENSOR:NE.CRANK
1 2 3 E76
0.75 0.75 0.75
B/Y L/Y W/B
SENSOR:OIL PRESSRE
PCV Ft
1 2
0.75 0.75
R/ L R /W
E161
1 2 3 1 2
PCV 1 0.5 0. 5 0.5 0.75 0.75
L/W Br L B/Y Y/G
E113 E93
SENSOR:COMMON RAIL SENSOR:FUEL TEMP
1
5
E112 B/W
1 2 3 SENSOR:CAM ANGLE(G) H22

0.5 0. 5 0 .5
Br L/W L
1 2 3 4
0.5 0.5 0.75
Y V/W B
5 6 7 8
0.5 0.75 0.75 0.75
Br B/W R /B R /W
4 3 2 1 9 10 11 12
1.25 1.25 0.75 0.75 0.75 0.5
W R W/B L /Y B /Y L
3 2 1 4 3 2 1 8 7 6 5 13 14 15 16
0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.5 0.5 0.75 0.75
Y/G R/W R/B G /Y G /W G /B L L / R L/ Y L / W Br L/W B/R L
6 5 4 8 7 6 5 12 11 10 9 17 18 19 20
0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
R/L R W /L W /B W / R G/R G/B R/L
H6 H8 H12 H20
TSWG0154
E75 E112
Terminal Terminal
Number Number
1 Boost pressure sensor GND 1 G sensor +
2 Boost pressure sensor Vout 2 G sensor GND
3 Boost pressure sensor Vcc 3 G sensor Vcc
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 PCV +B
2 EGR hall sensor W 2 PCV 1
3 EGR hall sensor V
E162
4 EGR hall sensor U
Terminal
5 EGR GND
Number
6 EGR motor W
1 PCV +B
7 EGR motor V
2 PCV 2
8 EGR motor U
E163
E90
Terminal
Terminal Number
Number
1 Boost temperature sensor GND
1 ECT GND
2 Boost temperature sensor +
2 ECT +
3 ECT meter H1
Terminal
E93 Number
Terminal 1 Glow
Number
1 Fuel temperature sensor GND H6
2 Fuel temperature sensor + Terminal
Number
E98 1 PCV 2
Terminal 2 PCV 1
Number
3 Fuel temperature sensor +
1 CKP GND
4 ECT meter
2 CKP +
5 PCV +B
6 —
H8 Terminal
Terminal Number
Number 14 Common rail pressure sensor GND
1 EGR hall sensor U 15 Boost temperature sensor +
2 EGR hall sensor V 16 Boost pressure sensor Vout
3 EGR hall sensor W 17 Boost pressure sensor GND
4 — 18 —
5 EGR motor U 19 —
6 EGR motor V 20 —
7 EGR motor W
H22
8 —
Terminal
Number
H12
1 Glow
Terminal
Number
H94
1 —
Terminal
2 —
Number
3 Injector power supply 2
1 —
2 OS — INJ1 signal/Injector #1
5 —
9 —
10 —
8 —
H20
Terminal
Number
1 CKP GND
2 CKP +
3 CKP shield
4 —
5 G sensor +
6 G sensor shield
7 ECT +
8 Boost pressure sensor Vcc
9 Engine oil pressure sensor Vcc
10 Engine oil pressure sensor Vout
11 Engine oil pressure sensor GND
12 Common rail pressure sensor Vcc
13 Common rail pressure sensor Vout
Cylinder head
H95
(Female connector on injector side)
In cylinder head
H94
(Female connector
on injector side)
H95
(Male connector on ECM side)
H94
(Male connector on ECM side)
TSWG0041
H94/H95 connector
Name
1. Engine harness-side connector
2. Cylinder head outside connector
3. Cylinder head inside connector
4. Injector harness-side connector
Connector list No. Connector Face
No. Connector Face
E-57
E-27
Machine harness side (female terminal)
#1 injector
(silver)
1 2 3
E-75
003-501
E-29 Engine harness side (male terminal)

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

(Black)
#3 injector
(silver)
E-80

(Black)
#4 injector
(silver)
1 2
E-90 3
003-500

(Light gray)
#5 injector
(silver)
E-93

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

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

(Black)
H-6

E-161 (Black)

(Light gray)
H-6

E-162

(Dark gray) H-8

(Black)
E-163

H-8
(Gray)
FB-124
Engine harness side (male terminal) H-12

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

Injector harness side (male terminal)
H-94

(Gray)
H-94
Cylinder head outside (female terminal)

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

(Dark gray)
List of Function Checks

List of function checks
Interview Inspection to comprehend the trouble symptom and diagnose properly based on a cus-
tomer’s complaint.
OBD system check Inspection to identify defective point of engine control system (inspection procedure)
Diagnosis lamp illumination cir- Inspection when diagnosis lamp does not come on when starter switch is turned ON.
cuit system check
Diagnosis lamp blinking circuit Inspection when diagnosis lamp does not blink (remains on) when diagnostic switch is
system check turned ON.
Scan tool power supply circuit Inspection when scan tool (Tech2) does not operate.
system check
Scan tool communication circuit Inspection when scan tool (Tech2) cannot communicate with ECM.
system check
Starting circuit system check Inspection when starter does not operate.
Starting system check Inspection when starter operates but engine does not start.
Fuel system check Inspection when relevant points to fuel system may be faulty (inspection procedure).
Intake system check Inspection when relevant points to intake system may be faulty (inspection procedure).
Exhaust system check Inspection when relevant points to exhaust system may be faulty (inspection procedure).
EGR control system check Inspection when relevant points to EGR may be faulty (inspection procedure).
QOS control system check Inspection when relevant points to QOS (glow) may be faulty (inspection procedure).
CAN communication check Inspection when fault relevant to machine control unit and CAN communication between
scan tool and ECM may exist.
Machine-side check Inspection when fault relevant to machine function (inspection procedure) may exist.
In the subsequent part of this manual, “scan tool” indicates scan tools including Tech2.
OBD system check
About OBD system check Note for OBD system check
OBD system check is systematic method to check the Important:
problems which caused by engine control system mal- • If there is no complaint for operationality,
function. It is the first procedure of all complaint diagno- never perform this diagnostic step unless oth-
sis for operationality. Use of this diagnostic step erwise instructed in other items.
properly enables to shorten the diagnosis period and to
• Before the diagnosis, check the service infor-
prevent unnecessary replacement of proper parts.
mation.
Test description • Never erase DTCs unless otherwise instructed
in the diagnostic step.
5. Communication disability with scan tool is caused by
• If fault is found in the engine starting system,
fault in the communication circuit between each ECU
refer to “Electrical system” in the service man-
and scan tool.
ual “Engine section”.
8. If DTC is detected, proceed to the relevant DTC
diagnosis by referring to 1E-270, “List of Diagnostic • Ensure the battery is fully charged.
Trouble Codes”. If more than one DTC is detected, • Make sure the battery cable is normal and
start with the one with smallest DTC number unless securely connected.
otherwise instructed in the diagnostic step. • Make sure the ground cable of ECM is con-
nected to the proper position securely.
Step Action Value YES NO

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

1. Check for following troubles.
• Engine stall
• Engine hunting, rough idling
• Engine output lowering, blow up fault,
engine breathing
9 • Exhaust gas contains a lot of white smoke. —
• Exhaust gas contains a lot of black smoke.
• Idling rotation cannot be adjusted.
• Idling rotation cannot be reduced. Go to the relevant
trouble symptom
Is the trouble detected? diagnosis. Normal system
Diagnosis lamp illumination circuit system check
(15A)*
A A
Meter
Machine
trouble
diagnosis
monitor
Diagnosis Engine oil QOS indicator Boost Tachometer
lamp pressure lamp lamp temperature
lamp
Machine
control
unit
CAN LOW CAN HIGH
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 8 E-57 Engine control

module (ECM)
Diagnosis lamp Engine oil QOS indicator Boost temperature

control pressure lamp lamp control lamp control
control
Tachometer signal
CAN HIGH CAN LOW
TSWG0075
Description of circuit Following inspections are necessary to detect these

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

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

4 Is EMPS available? — Go to Step 5. Go to Step 6.
1. Check the version of ECM software.
Refer to 1E-88, “Flash Tool (EMPS)” in this
section for check and rewriting of ECM.
2. Rewrite the software if version upgraded is
necessary.
Note:
5 —
EGR valve position learning is required after
replacing or rewriting the ECM.
Refer to 1E-197, “Installation of ECM, Engine con-
trol module (ECM), Engine Control System” in this
section for learning of EGR. Check the repair,
and Go to “OBD
Is the procedure completed? system check”. —
Replace the ECM.
Note:
6 Refer to 1E-197, “Installation of ECM, Engine con- —
section for learning of EGR. Check the repair,
and Go to “OBD
Is the procedure completed? system check”. —
Diagnosis lamp blinking circuit system check
CAN LOW CAN HIGH

Engine
control
module
(ECM)
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
6 FL-150 7 FL-150
DLC
Machine
5 FL-150 4 FL-150 control unit
CAN HIGH CAN LOW
TSWG0074
Description of circuit Following inspections are necessary to detect these

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

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

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

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

1. Check for followings in the circuit between
ECM and diagnosis connector using breaker
box or DMM.
Refer to 1E-241, “Breaker box inspection pro-
cedure, Diagnosis lamp blinking circuit system
check, List of Function Checks”.
Note:
If breaker box is not available, refer to 1E-242,
3 “On-board check procedure for sensors, Diagnosis —
lamp blinking circuit system check, List of Function
Checks”.
• Open circuit
• High resistance

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

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


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

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

checked method value value
3 Open circuit/ Resistance • Key switch “OFF” 52 – Diagnosis con- 100Ω or less 10 MΩ or
high resistance measurement nector terminal more
Short circuit to Resistance • Key switch “OFF” 52 – Ground 10 MΩ or 100Ω or less
ground measurement more
On-board check procedure for sensors
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the har-
ness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
Scan tool power supply circuit system check
TSWG0162
Name
1. Battery cable 2. Power socket cable (AC/DC adapter)
Description of circuit • Improper connection of harness connector and

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

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

1. Connect the scan tool to the machine.
2. Turn the power switch of the scan tool to “ON”. Check the repair,
5 —
and Go to “OBD
Does the scan tool powered “ON”? system check”. Go to Step 1.
Scan tool communication circuit system check
CAN LOW CAN HIGH

Engine
control
module
(ECM)
KWP2000
52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57
6 FL-150 7 FL-150
DLC
Machine
5 FL-150 4 FL-150 control unit
CAN HIGH CAN LOW
TSWG0074
Description of circuit – Unmatched terminals are fitted.

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

Perform the OBD system check.
1 — Go to “OBD system
Is the procedure completed? Go to Step 2. check”.
Check for installation condition of the ECM connec-
tor and coupling connector.
2 1. Check for play or looseness in the connection. —


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

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

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


Replace the ECM.
Note:

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

Name
1. Breaker box
2. DMM

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

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

relay cut relay cut relay Main relay
(10A)*
1 H-22
0.5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START
Glow Glow relay Engine

plug control control
module
(ECM)
Starter cut
relay signal
TSWG0072
Starter safety relay control
Starter
B
Battery Generator
(100A)* L
(15A)* (60A)*
B C
Safety relay
L S
Glow
relay
A A
1 H-22
B Br C B ACC Br C
0.5 (ON) (ST) (ON) (ST)
B/W
OFF OFF
ON ON
START START
1 H-1
Key switch
10 E-57
Glow relay Engine

control control
Glow module
plug (ECM)
TSWG0073
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
– Check the relevant items on the scan tool data
• Worn harness cladding Test description
• Wire disconnection inside harness cladding Numbers below indicate step numbers in the diagnostic
Following inspections are necessary to detect these chart.
causes. 1. If these DTCs are detected, engine may not start.
ECM connector
– Poor connection of terminal from connector
3. 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”.

2. Check the DTC.
1 — Go to the relevant
Is the DTC P0340, P0341, P0615, P1345 or P1625 diagnosis of DTC
detected? detected. Go to Step 2.
2 Is the scan tool available? — Go to Step 3. Go to Step 16.
1. Turn the key switch to “START”.
2. Check for “Starter switch (ST)” on the data dis-
3 play using scan tool. —
Is the “Starter switch (ST)” displayed “ON”? Go to Step 5. Go to Step 4.

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

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

Replace the starter cut relay.
6 —
2. Remove the starter relay.
3. Connect the battery to the starter relay coil-
7 side terminal. —
4. Check for continuity between the starter relay
switch-side terminals.

Replace the starter relay.
8 —
9 — Go to “Diagnostic
Does the starter operate? aid”. Go to Step 10.

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
10 • Between starter relay and ground —
• Between starter relay and starter

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

necessary.
Note:
13 —

Replace the ECM.
Note:

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


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

Replace the starter cut relay.
18 —
2. Remove the starter relay.
3. Connect the battery to the starter relay coil-
19 side terminal. —
4. Check for continuity between the starter relay
switch-side terminals.

Name
1. Breaker box
2. DMM

4, 16 Open circuit/ Resistance • Key switch “OFF” 46 – Key switch 100Ω or less 10 MΩ or
high resistance measurement “START” terminal more
5, 17 Open circuit/ Resistance • Key switch “OFF” Starter cut relay 100Ω or less 10 MΩ or
high resistance measurement • Relay alone Switch-side terminal more
7, 19 Open circuit/ Resistance • Key switch “OFF” Starter relay 100Ω or less 10 MΩ or
high resistance measurement • Relay alone Switch-side terminal more
• Relay “ON”
2 1
TSWG0197
Name
machine
2. Machine harness
3. Sensor connector
4. Engine harness

open circuit.
Starting system check
5 (15A)*
Main relay
H-6
0.75
R/L
1 E-162 1 E-161
PCV2 PCV1
2 E-162 2 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)
TSWG0077
About starting system check Diagnostic aid

Starting system check is systematic method to detect If there is relevant DTC to CKP sensor and G sensor,
the cause of that engine does not start. Followings are the engine will not start until memory clear is per-
the preconditions for performing this diagnosis. formed.
• Battery is fully charged, and battery cable is If the intermittent trouble is suspected, followings may
securely connected. be the cause.
• Engine speed at cranking is normal. • Improper connection of harness connector
• Sufficient amount of fuel is supplied. • Defective harness routing
• No air mixed in the fuel. • Worn harness cladding
• Air cleaner element and fuel filter is normal. • Wire disconnection inside harness cladding
• Correct fuel is used.
causes.
Important: • Improper connection of harness connector and
Start with the DTC diagnosis relevant to fuel sys- ECM connector
tem if there is any. – Poor connection of terminal from connector
– Unmatched terminals are fitted.
– Damage of connector lock 3. If the PCV-LOW circuit is shorted to ground, the PCV
– Poor contact between terminal and wire drive current will not increase to more than 900mA.
4. If the engine starts with the PCV connector discon-
Test description nected, PCV 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. 5. Check the signal and operation of each sensor and
injector.

2. Crank the engine for 15 seconds.
1 3. Check the DTC. — Go to the relevant
diagnosis of DTC
Is DTC detected? detected. Go to Step 2.
While cranking the engine, check for “PCV F/B” on
3 the data display using scan tool. 900mA
Is the “PCV F/B” less than the specified value? Go to Step 4. Go to Step 5.
1. Remove the PCV connector.
4 2. Crank the engine. —
Go to DTC P0091/ Go to “Fuel system
Does the engine start? P1291. check”.
Repair the PCV-LOW circuit between the ECM and
5 the PCV. —
1. Check the relevant items to the following using
scan tool to see if the values are normal.
(Refer to “Tech2 data reference valve” for
specified valve.)
• Engine coolant temperature (ECT) sensor
• Common rail pressure sensor
6 • EGR position sensor —
• Injector
2. If the trouble is detected, replace the circuit or

sensor as required.

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

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

Check the DTC. Go to the relevant Check the repair,
9 — diagnosis of DTC and Go to “OBD
Is DTC detected? detected. system check”.

1. Check the PCV-LOW circuit between the ECM
and the PCV.
10 2. If the trouble is detected, repair the circuit as —
required.

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

Fuel system check
TSWG0143
Name
1. Common rail 5. Pre-filter
2. Fuel filter 6. Feed pump
3. Injector 7. Supply pump
4. Fuel tank
About fuel system • Worn harness cladding

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

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

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

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

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

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

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

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

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

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

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

Repair or replace the turbocharger.
Note:
6 For work procedure, refer to “Engine section” in the —
service manual.

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

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

Check for crush, breakage, or exhaust leakage in
1 the exhaust pipe and tail pipe. —
Repair or replace the exhaust pipe or tail pipe.
2 —
Repair the machine.
3 —
EGR control system check
EGR EGR EGR

position position position
G sensor Common rail pressure sensor sensor sensor
signal sensor signal signal signal signal Engine
5V control
module
(ECM)
B+ B+ B+
98 E-56 101 E-56 100 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
5 H-20 14 H-20 6 H-20 13 H-20 12 H-20 3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8
0.5 0.5
Br L/W 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
0.5 L GY W/L G/W W/B G/B W/R L/W
L
1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.5 0.5 0.5
B/W L/W Br L
1 E-112 2 E-112 3 E-112 1 E-113 2 E-113 3 E-113 V
W U
EGR position sensor/EGR motor
EGR valve
G sensor Common rail pressure sensor
TSWG0080
Description of circuit
The ECM operates the EGR valve based on engine
speed, engine coolant temperature, intake air tempera-
ture, fuel injection amount, and barometric pressure.
The EGR motor drives the EGR valve, and the EGR
position sensor detects the EGR valve opening angle.

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

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

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

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

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

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

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

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.
9 —

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

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

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

relay cut relay cut relay Main relay
(10A)*
1 H-22
0.5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START
Glow Glow relay Engine

plug control control
module
(ECM)
Starter cut
relay signal
TSWG0072
(15A)*
A A
Meter
Machine
trouble
diagnosis
monitor
Diagnosis Engine oil QOS indicator Boost Tachometer
lamp pressure lamp lamp temperature
lamp
Machine
control
unit
CAN LOW CAN HIGH
37 E-57 18 E-57 6 E-57 17 E-57 11 E-57 7 E-57 8 E-57 Engine control

module (ECM)
Engine oil QOS indicator

Diagnosis lamp Boost temperature
control pressure lamp lamp control lamp control
control
Tachometer signal
CAN HIGH CAN LOW
TSWG0075
Note: Test description

The QOS circuit is the same for both the starter ECM
Numbers below indicate step numbers in the chart.
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.
1 — Go to “OBD system
Is the procedure completed? Go to Step 2. check”.

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

Repair the short circuit between the fuse, ECM,
5 glow plug, and QOS indicator lamp. —
Is the procedure completed? — Go to Step 6.
1. Replace the fuse.
6 —
3. Make sure that the fuse is not blown.
Is the procedure completed? — Go to Step 7.

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.
Does the QOS indicator lamp come on? Go to Step 12. Go to Step 10.
1. Disconnect the ECM connector.
2. Measure the resistance between the QOS indi-
10 cator lamp terminal-to-ECM harness and the 10 MΩ or more
ground.

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

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

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

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

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

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

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

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

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


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

specified value? Go to Step 22. Go to Step 16.
1. Turn the glow relay “OFF” using the “Glow plug
the glow relay.
using DMM.
Are the voltages at all the cylinders specified

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

List of diagnostic trouble codes for Hitachi Construction Machinery Co., Ltd.
On some machines, the diagnosis lamp comes on instead of trouble display monitor on the machine.
Fault Recovery
Flash DTC Item to be Preconditions when Behavior when Diagno-
DTC DTC set condition judgment from
code description detected DTC is set trouble occurs sis lamp
period failure
P0088 118 Common rail Common rail • Key switch input Rail pressure is Approx. 5 Intense engine ON *1
pressure fault pressure voltage is 16V or more than 150 sec. vibration, rough
(1st stage) abnormal more. MPa (21756 psi). idling, output lower-
increase • DTC P0088, ing, blow up fault,
P0192, P0193 or black smoke emit-
P1635 is not ted, and excessive
detected. output are possible.
• Actual rail pressure Back-up:
is 2 MPa (290 psi) or Limited injection
more, and 70 rpm or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
Common rail Common rail • Key switch input Common rail Approx. 5 Intense engine ON *1
pressure fault pressure voltage is 16V or pressure fault (1st sec. vibration, rough
(2nd stage) abnormal more. stage) is com- idling, output lower-
increase • DTC P0088, pleted, and rail ing, blow up fault,
P0192, P0193 or pressure is more black smoke emit-
P1635 is not than 155 MPa ted, and excessive
detected. (22481 psi). output are possible.
• Actual rail pressure Back-up:
is 2 MPa (290 psi) or Limited injection
more, and 70 rpm or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0089 151 Common rail Common rail • Key switch input Actual rail pres- Approx. 8 Intense engine ON *1
pressure fault pressure voltage is 16V or sure lower than sec. vibration, rough
(Excessive abnormal more. target rail pres- idling, output lower-
pressure feed increase • DTC P0089, sure for 10 MPa ing, blow up fault,
in pump) P0192, P0193 or (1450 psi) or black smoke emit-
P1635 is not more holds 8 sec- ted, and excessive
detected. onds or more. output are possible.
• Coolant tempera- Or actual rail Back-up:
ture is 60°C (140°F) pressure higher Limited injection
or more, and 375 than target rail amount 3 (multi-
rpm or more. pressure for 10 injection stopped)
MPa (1450 psi) or Target RP upper
more holds 8 sec- limit (80 MPa
onds or more, {11603 psi})
during indication
of no pressure
feed.
P0091 247 PCV1 open PCV1 electri- • Main relay power PCV1 monitor Approx. 1 Intensive engine ON *2
circuit or cal wiring supply voltage is signal is fixed to sec. vibration, rough
ground short open circuit/ 16V or more. Low-side. idling, output lower-
ground short • DTC P0092 is not ing, blow up fault,
detected. black smoke emitted
• 300 rpm or more, Back-up:
or actual rail pres- Limited injection
sure exceeds target amount 3 (multi-
rail pressure. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
Fault Recovery
period failure
P0092 217 PCV1+B PCV1 electri- • Main relay power PCV1 monitor Approx. 1 Intensive engine ON *1
short circuit cal wiring +B supply voltage is signal is fixed to sec. vibration, rough
short 16V or more. High-side. idling, output lower-
• DTC P0091 or ing, blow up fault,
P0092 is not black smoke emitted
detected. Back-up:
• 300 rpm or more, PCV1 stop
or actual rail pres-
sure exceeds target
rail pressure.
P0107 71 Barometric Open/short • Key switch input Barometric pres- Approx. 5 Due to back-up ON *2
pressure sen- circuit/deteri- voltage is 16V or sure sensor volt- sec. equivalent to 2500m
sor fault (low oration of more. age is lower than (8200ft)
voltage fault) sensor or • DTC P1630 or 0.5 V. • Black smoke emit-
harness P1632 is not ted at high altitude
detected. • Output shortage at
low altitude
Back-up:
Barometric pres-
sure default set-
ting (80 kPa {11.6
psi})
EGR stopped
P0108 Barometric Short circuit • Key switch input Barometric pres- Approx. 5 Due to back-up ON *2
pressure sen- in sensor or voltage is 16V or sure sensor volt- sec. equivalent to 2500m
sor fault (high harness more. age is more than (8200ft)
voltage fault) • DTC P1630 or 3.8 V. • Black smoke emit-
P1632 is not ted at high altitude
detected. • Output shortage at
low altitude
Back-up:
Barometric pres-
sure default set-
ting (80 kPa {11.6
psi})
EGR stopped
P0112 22 Intake air Short circuit • Key switch input Intake air temper- Approx. 4 White smoke emis- ON *2
temperature in sensor or voltage is 16V or ature sensor volt- sec. sion possible when
sensor fault harness more. age is less than starting at low tem-
(low voltage • DTC P1630 or 0.1 V. peratures
fault) P1632 is not Back-up:
detected. Intake air tempera-
ture default setting
(at starting: −10°C
{14°F}, at running:
25°C {77°F})
EGR stopped
P0113 Intake air Open/short • Key switch input Intake air temper- Approx. 4 White smoke emis- ON *2
temperature circuit/deteri- voltage is 16V or ature sensor volt- sec. sion possible when
sensor fault oration of more. age is more than starting at low tem-
(high voltage sensor or • DTC P1630 or 4.95 V. peratures
fault) harness P1632 is not Back-up:
detected. Intake air tempera-
• 3 minutes or more ture default setting
has elapsed after (at starting: −10°C
starting engine. {14°F}, at running:
25°C {77°F})
EGR stopped
Fault Recovery
period failure
P0117 23 Engine cool- Short circuit • Key switch input Engine coolant Approx. 4 Start ability deterio- ON *2
ant tempera- in sensor or voltage is 16V or temperature sen- sec. rates at low temper-
ture sensor harness more. sor voltage is less atures or black
fault (low volt- • DTC P1630 or than 0.1 V. smoke emission is
age fault) P1633 is not possible, output low-
detected. ering depending on
conditions.
Back-up:
Coolant tempera-
{−4°F}, at running:
80°C {176°F})
EGR stopped
P0118 Engine cool- Open/short • Key switch input Engine coolant Approx. 4 At normal tempera- ON *2
ant tempera- circuit/break- voltage is 16V or temperature sen- sec. ture: Black smoke
ture sensor age of sen- more. sor voltage is emission, greater
fault (high sor or • DTC P1630 or more than 4.85 V. engine combustion
voltage fault) harness P1633 is not noise possible.
detected. During idling at low
• 3 minutes or more atmospheric temper-
has elapsed after atures: Rough idling,
starting engine. engine stall, white
smoke emission
possible.
Back-up:
Coolant tempera-
80°C {176°F})
EGR stopped
P0182 211 Fuel temper- Short circuit • Key switch input Combustion tem- Approx. 4 Operationality is ON *2
ature sensor in sensor or voltage is 16V or perature sensor sec. affected.
fault (low volt- harness more. voltage is less Back-up:
age fault) • DTC P1630 or than 0.1 V. Fuel temperature
P1633 is not default setting
detected. (at starting: −20°C
70°C {158°F})
P0183 Fuel temper- Open/short • Key switch input Combustion tem- Approx. 4 Not in particular ON *2
ature sensor circuit/break- voltage is 16V or perature sensor sec. Back-up:
fault (high age of sen- more. voltage is more Fuel temperature
voltage fault) sor or • DTC P1630 or than 4.85 V. default setting
harness P1633 is not (at starting: −20°C
detected. {−4°F}, at running:
• 3 minutes or more 70°C {158°F})
has elapsed after
starting engine.
Fault Recovery
period failure
P0192 245 Common rail Short circuit • Key switch input Common rail Nearly Engine blow up ON *2
pressure sen- in sensor or voltage is 16V or pressure sensor simulta- Back-up:
sor fault (low harness more. voltage is less neous to Actual rail pres-
voltage fault) • DTC P1630 or than 0.7 V. fault sure default value
P1635 is not occur- (80Mpa {11603
detected. rence psi})
Rail pressure feed-
back control
stopped
Limited injection
amount 2 (multi-
injection stopped)
P0193 Common rail Open/short • Key switch input Common rail Nearly Output lowering, ON *2
pressure sen- circuit/break- voltage is 16V or pressure sensor simulta- Black smoke emit-
sor fault (high age of sen- more. voltage is more neous to ted
voltage fault) sor or • DTC P1630 or than 4.5 V. fault Engine stall possible
harness P1635 is not occur- Back-up:
detected. rence Actual rail pres-
sure default set-
ting (80 Mpa
{11603 psi})
Rail pressure feed-
back control
stopped
Limited injection
amount 2 (multi-
injection stopped)
P0201 271 Open circuit Open/short • Main relay power No injector 1 Approx. 3 Intensive engine ON *1
in injection circuit in elec- supply voltage is monitor input sig- sec. vibration, rough
nozzle #1 trical wiring 16V or more. nal exists. idling, output lower-
drive system No. 1 cylinder • 70 rpm or more ing, blow up fault
injector • DTC P0611, Back-up:
P1261 or P0201 is Injection for cylin-
not detected. der #5 stopped,
Fault Recovery
period failure
P1262 or P0206 is Common 1 stop
not detected. (#1, #2, #3 cylin-
ders stopped)
P0219 543 Overrun Engine speed • Key switch input When engine Nearly Output lowering ON *2
abnormally voltage is 16V or speed is more simulta- Back-up:
high more. than 1970 rpm. neous to Limited injection
fault amount 1
occur- Limitation is lifted
rence if the speed
decreases
P0237 32 Boost pres- Open/short • Key switch input Boost pressure Approx. 3 Operationality is ON *2
sure sensor circuit/break- voltage is 16V or sensor voltage sec. affected.
fault (low voltage of sen- more. less than 0.1 V Back-up:
age fault) sor or • DTC P1630 or Boost pressure
harness P1634 is not default setting (200
detected. kPa {29.0 psi})
Boost pressure
correction/EGR
stopped
P0238 Boost pres- Short circuit • Key switch input Boost pressure Approx. 3 Black smoke emit- ON *2
sure sensor in sensor or voltage is 16V or sensor voltage is sec. ted
fault (high harness more. more than 4.9 V. Back-up:
voltage fault) • DTC P1630 or Boost pressure
P1634 is not default setting (200
detected. kPa {29.0 psi})
Boost pressure
correction/EGR
stopped
P0335 15 Crank sen- Open circuit • G sensor pulse is G sensor signal When • Output lowering, ON *1
sor fault (no in sensor/wir- normal. exists but no trouble white smoke emis-
signal) ing • DTC P0335, crank signal. occurs 14 sion, intense engine
P0336, P0340, out of 21 vibration possible
P0341 or P1345 is samples. • Engine stall possi-
not detected. ble (restart is possi-
• Engine is running. ble when G sensor
is normal.)
Back-up:
Control based on
G sensor when it is
normal
P0336 Crank sen- Broken teeth/ • G sensor pulse is Number of pulse When • Output lowering, ON *1
sor fault (sig- unnecessary normal. for crank signal is trouble white smoke emis-
nal fault) signal mixed • DTC P0335, mismatched. occurs 14 sion, intense engine
(such as P0336, P0340, out of 21 vibration possible
short circuit P0341 or P1345 is samples. • Engine stall possi-
with other not detected. ble (restart is possi-
wiring) • Engine is running. ble when G sensor
is normal.)
Back-up:
Control based on
G sensor when it is
normal
Fault Recovery
period failure
P0340 14 G sensor Open circuit • Key switch input Crank signal When • Behavior does not ON *1
fault (no sig- in sensor/wir- voltage is 16V or exists but no G trouble change during
nal) ing more. sensor signal. occurs 7 engine running.
• Crank pulse is nor- out of 8 • After engine stalls,
mal. samples. engine will not start.
• DTC P0335, Back-up:
P0336, P0340, Engine running
P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
• Engine is running. Unable to identify
cylinder (unable to
restart)
P0341 G sensor Broken teeth/ • Key switch input Number of pulse When • Behavior does not ON *1
fault (signal unnecessary voltage is 16V or for G sensor sig- trouble change during
fault) signal mixed more. nal is mis- occurs 7 engine running.
(such as • Crank pulse is nor- matched. out of 8 • After engine stalls,
short circuit mal. samples. engine will not start.
with other • DTC P0335, Back-up:
wiring) P0336, P0340, Engine running
P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
• Engine is running. Unable to identify
cylinder (unable to
restart)
P0380 66 Glow relay Open/short • Key switch input Glow relay drive When Operationality is not ON *1
fault circuit/dam- power supply volt- instruction signal trouble affected.
age of relay age is higher than is unmatched with occurs 25 Back-up:
or harness 16 V but lower than glow relay moni- out of 30 No back-up action
32 V. tor signal. samples.
P0381 67 Glow lamp Open/short • Key switch input Glow lamp drive When Operationality is not ON
fault circuit/dam- voltage is 16V or instruction signal trouble affected.
age of lamp more. is unmatched with occurs 25 Back-up:
or harness • DTC P0381 is not glow lamp moni- out of 30 No back-up action
detected. tor signal. samples.
P0487 44 EGR position Open/short • Main relay input EGR position out- Approx. 3 Operationality is not ON *2
fault (Brush- circuit/break- voltage is 16 V or put signal is sec. affected.
less specifi- age of sen- more. abnormal. Back-up:
cation) sor or • DTC P1630 or Instruction to fully
harness P1635 is not

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Titluri conexe

Introduction

Hitachi Construction Machinery Co.,Ltd

Engine Manual (2/2)

How to Use This Manual

How to use this manual

Precautions on service work

Procedure of trouble diagnosis

How to use trouble diagnosis-related tool

Engine control system

List of function checks

List of diagnostic trouble codes

List of trouble symptom

Abbreviation Name Meaning and remarks

About colors of wirings

Green (base color)

Symbol Color Symbol Color

Vehicle speed Engine oil pressure

CKP CKP Engine coolant

3 H-6 7 H-20 11 H-20 10 H-20 9 H-20

0.75 0.75 0.75

0.75 B 2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

Precautions on Service Work

Commercial electrical equipment Caution:

Damage caused by electrostatic discharge 3 2 1

The electronic components used in the electronic con-

a person slides on the seat of the machine. TSWG0167

Procedure of Trouble Diagnosis

Data Link Connector

Read DTC Actuator Test

Step 2 Perform pre-inspection

Step 3 Check service information

Step 4 Check according to each DTC

Step 5 Perform fault inspection for each symptom

2. Middle stage of fault;

• The fault occurs for a short period and singly,

but repeats intermittently and definitely occurs

Name under a specific condition. A customer’s com-

2. Evaluate the trouble information correctly.

Points for interview

• What Trouble symptom

Check list for engine control system

Fault in related system Diagnosis lamp

t1=approx. 0.3 sec.

Tens digit Units digit

Hundreds digit Tens digit Units digit

If there is no applicable symptom

If there is intermittent (intermittent trouble)

List of final check items

No. Item Purpose Method

Confirmation of powerful electric wave transmitter; if Caution:

Clear with memory clear switch

Isuzu scan tool (Tech2) and the scan tools with KW

About scan tool display

Tech2, KW display CAN display

About scan tool (Tech2)

Data Link Connector

Read DTC Actuator Test

This menu can be used to display the current data.