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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.
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
Electronic Control Fuel Injection System (Common Rail Type) 1E-3
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
1E-4 Electronic Control Fuel Injection System (Common Rail Type)
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.)
e.g.
Red (stripe color)
Harness size(0.5mm2)
Name
1. Single color
2. Color stripe
Engine control
module (ECM)
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
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.
1E-8 Electronic Control Fuel Injection System (Common Rail Type)
How to read trouble diagnosis section
The following illustration is an example for trouble diagnosis section. See this illustration and description.
Electronic Control Fuel Injection System (Common Rail Type) 1E-9
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.
1E-10 Electronic Control Fuel Injection System (Common Rail Type)
Name
1. Injector pipe
2. Flow damper
3. Common rail
4. Common rail pressure sensor
5. Pressure limiter
Electronic Control Fuel Injection System (Common Rail Type) 1E-11
• 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.
1E-12 Electronic Control Fuel Injection System (Common Rail Type)
ECM control
DTC
Sensor output
V
V
RPM
RPM
Snapshot V
V
%
TSWG0121
Electronic Control Fuel Injection System (Common Rail Type) 1E-13
Trouble diagnostic procedure
Step 1 Confirm the user’s complaint
• Organize the trouble conditions using a check list.
TSWG0156
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-15
TSWG0155
1E-16 Electronic Control Fuel Injection System (Common Rail Type)
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.
At code [23]
Goes off
At code [413]
ON
Goes off
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)
Electronic Control Fuel Injection System (Common Rail Type) 1E-21
Value
TSWG0182
Name
1. Tech2 and scan tool with KW communication
2. Scan tool with CAN communication
ECM control
DTC
Sensor output
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
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-25
1 5
3 4
TSWG0148
Name
1. PCMCIA card 4. DLC cable
2. SAE 16/19 adapter 5. Tech2
3. Power cable
1E-26 Electronic Control Fuel Injection System (Common Rail Type)
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)
TSWG0115
TSWG0116
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.
1E-30 Electronic Control Fuel Injection System (Common Rail Type)
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
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.
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-31
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”.
TSWG0084
Note:
Except industrial engine.
WARNING:
Press [ENTER] While this function is under execution, do not con-
nect the unit to the machine!
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-33
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
TSWG0161
1E-34 Electronic Control Fuel Injection System (Common Rail Type)
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
TSWG0110
TSWG0090
TSWG0088
Note:
Select the model year of the relevant machine by
checking VIN of each machine.
Electronic Control Fuel Injection System (Common Rail Type) 1E-35
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
d
TSWG0094
DTC check
1. Select “F0: Diagnostic Trouble Codes” on the
“Engine” screen.
TSWG0123
If DTC stored
TSWG0095
TSWG0098
V V
V V
RPM RPM
RPM RPM
V V
V V
% %
MPa MPa
TSWG0099
1E-38 Electronic Control Fuel Injection System (Common Rail Type)
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.
TSWG0102 TSWG0104
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
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
TSWG0124
Softkey functions
Choose the “More” on the snapshot graph display
screen.
• Move ←: Allows to view changes of data preceding TSWG0125
the display screen.
Electronic Control Fuel Injection System (Common Rail Type) 1E-41
• 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
TSWG0107
Actuator test
TSWG0130
TSWG0127
V
V
RPM RPM
MPa RPM
V
V
%
TSWG0139
TSWG0131
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.
TSWG0134
TSWG0137
TSWG0140 TSWG0110
5. Send the instruction to EGR valve and check the 2. Press [ENTER].
data list.
%
%
%
TSWG0108
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-47
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
Step 1
• Press [ENTER].
TSWG0110
1E-48 Electronic Control Fuel Injection System (Common Rail Type)
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-49
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/
down) keys or F4 (function) key, and press
[ENTER].
1E-50 Electronic Control Fuel Injection System (Common Rail Type)
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-51
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
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.
1E-52 Electronic Control Fuel Injection System (Common Rail Type)
TSHK0059 TSHK0099
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.
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
Electronic Control Fuel Injection System (Common Rail Type) 1E-53
TSHK0101 TSHK0103
TSHK0102
Step 15-5
• If the entered values meet the conditions in Step TSHK0104
1 2 3 4
TSHK0105
TSHK0098
Name
1. Engine number
2. Typical engine model
3. Q adjust information
4. Injector information
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-55
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.
Step 1
• Press [ENTER].
TSWG0089
Step 4
• Choose the menu (Off-Road) Industrial Engine
with ▲, ▼ (up/down) keys, and press the [ENTER]
key.
TSWG0110
Step 2
• Choose the menu F0: Diagnostics with ▲, ▼ (up/
down) keys or F0 (function) key, and press
[ENTER].
1E-56 Electronic Control Fuel Injection System (Common Rail Type)
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
• Choose 6HK1-TC (C/Rail_TIER3) with ▲, ▼ (up/
down) keys, and press [ENTER].
Electronic Control Fuel Injection System (Common Rail Type) 1E-57
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].
• This displays the ECU ID information.
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.
1E-58 Electronic Control Fuel Injection System (Common Rail Type)
TSHK0067 TSHK0069
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-59
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.
1E-60 Electronic Control Fuel Injection System (Common Rail Type)
TSHK0074 TSHK0076
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-61
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.
1E-62 Electronic Control Fuel Injection System (Common Rail Type)
ID code upload (Tech2)
Step 1
• Press [ENTER].
TSWG0089
Step 4
• Choose the menu (Off-Road) Industrial Engine
TSWG0110
with ▲, ▼ (up/down) keys, and press the [ENTER]
key.
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-63
TSWG0091 TSWG0093
TSWG0122
TSWG0092 Step 8
• Press the softkey [Confirm].
Step 7
• This displays the ECU ID information.
• Press the softkey “Confirm”.
• The ignition is ON at this time.
1E-64 Electronic Control Fuel Injection System (Common Rail Type)
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].
Electronic Control Fuel Injection System (Common Rail Type) 1E-65
Step 11-1 Step 12-1
TSHK0061 TSHK0061
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.
1E-66 Electronic Control Fuel Injection System (Common Rail Type)
TSHK0064
Step 12-4
• Pressing the softkey [Confirm] returns you to Step
11.
TSHK0065
Electronic Control Fuel Injection System (Common Rail Type) 1E-67
ID code download (ECM)
Step 1
• Press [ENTER].
TSWG0089
Step 4
• Choose the menu (Off-Road) Industrial Engine
TSWG0110
with ▲, ▼ (up/down) keys, and press the [ENTER]
key.
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.
1E-68 Electronic Control Fuel Injection System (Common Rail Type)
TSWG0091 TSWG0093
TSWG0122
TSWG0092 Step 8
• Press the softkey [Confirm].
Step 7
• This displays the ECU ID information.
• Press the softkey “Confirm”.
• The ignition is ON at this time.
Electronic Control Fuel Injection System (Common Rail Type) 1E-69
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].
1E-70 Electronic Control Fuel Injection System (Common Rail Type)
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-71
TSHK0093 TSHK0095
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.
1E-72 Electronic Control Fuel Injection System (Common Rail Type)
TIS2000
TIS 2000 installation procedure
(Time needed: 30 minutes)
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
1E-74 Electronic Control Fuel Injection System (Common Rail Type)
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
Icons to be displayed
The following icons are used for data display.
Uploads the snapshot data from the floppy disk or hard disk.
Displays the data parameters in graph and list (up to 3 parameter items for graph display).
Trigger of record: Moves to the trigger position and displays the snapshot.
Regeneration in forward direction: Replays all the snapshot in the forward direction.
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.
[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.
[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.
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-83
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.
1E-84 Electronic Control Fuel Injection System (Common Rail Type)
• 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.
2. Turn the key switch to OFF.
3. Disconnect the injector connector from engine on
the machine. (4-cylinder: one, 6-cylinder: two)
4HK1
TSWG0215
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
TSWG0214
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.
1E-86 Electronic Control Fuel Injection System (Common Rail Type)
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-87
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
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.
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.
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.
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.
1E-96 Electronic Control Fuel Injection System (Common Rail Type)
1.2 EMPS Selector Connection
6
DATA ECM
SELECT POWER
POWER READY READ ON
2 WRITE OFF
3 1
5 7
Using battery 5
6
DATA ECM
SELECT POWER
POWER READY READ ON
2 WRITE OFF
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)
Caution:
• Do not use an AC adapter at the same time
when drawing power from a battery.
Electronic Control Fuel Injection System (Common Rail Type) 1E-97
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.
Name
1. Normal Update Check the content, and click the [OK] button to
2. Enforce Update advance to next.
3. Campaign Update
WindowsXP
Battery Connection
Windows2000
Windows2000
Turn on the power switch, and then click the [Next] but-
ton.
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.
Configure the switch settings as shown below. Configure the switch settings as shown below.
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.”
1E-108 Electronic Control Fuel Injection System (Common Rail Type)
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.”
Note:
One of the messages shown below will appear if an
error occurs during reflashing.
(Refer to “8. Error Code List.”)
Electronic Control Fuel Injection System (Common Rail Type) 1E-109
2.17 Switch Confirmation Screen 6
Configure the switch settings as shown below. Clicking the [Next] button displays the message shown
below.
DATA SELECT switch: READ
ECM POWER switch: ON
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).”
1E-112 Electronic Control Fuel Injection System (Common Rail Type)
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.”
DATA SELECT switch: READ
ECM POWER switch: OFF
3.1 Startup
Double-click the “EMPS” icon on your Windows desk-
top to display the initial startup screen.
WindowsXP
Battery Connection
Windows2000
Windows2000
Turn on the power switch, and then click the [Next] but-
ton.
Clicking the [Yes] button after checking the connection Clicking the [Yes] button after checking the voltage of
of external power supply advances to “3.6 Selection power supply advances to “3.6 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 “3.5 Selection Menu.” ton to return to “3.5 Selection Menu.”
Clicking the [Help] button will display the message Clicking the [Help] button will display the message
shown below. shown below.
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
Electronic Control Fuel Injection System (Common Rail Type) 1E-123
Selection Item Descriptions
Items Settings/Operation Performed
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.
4.1 Startup
Double-click the “EMPS” icon on your Windows desk-
top to display the initial startup screen.
4.3.3 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].
Battery Connection 2. On [Control Panel], open [System].
3. When system properties appear, select [Hard-
ware].
WindowsXP
Windows2000
1E-132 Electronic Control Fuel Injection System (Common Rail Type)
4.4 Switch Confirmation Screen 1
After checking to make sure that the initial settings of
the switches are as shown on the screen, click the
[Next] button.
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.
Configure the switch settings as shown below. Configure the switch settings as shown below.
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.”
shown below, and advance to “4.22 Switch Confirma-
tion Screen 7.” 4.23 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 “4.24 Switch Confirmation Screen 8.”
If confirmation is not possible, click the [No] button to
return to “4.20 ECM Replacement / Data Confirmation.”
Electronic Control Fuel Injection System (Common Rail Type) 1E-147
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.”
Note:
One of the messages shown below will appear if an
error occurs during reflashing. (Refer to “8. Error Code
List.”)
1E-148 Electronic Control Fuel Injection System (Common Rail Type)
4.26 Switch Confirmation Screen 9
The switch confirmation screen is shown below.
Configure the switch settings as shown below. Clicking the [Next] button displays the message shown
below.
DATA SELECT switch: READ
ECM POWER switch: ON
5.1 Startup
Double-click the “EMPS” icon on your Windows desk-
top to display the initial startup screen.
WindowsXP
Battery Connection
Windows2000
Windows2000
Turn on the power switch, and then click the [Next] but-
ton.
Clicking the [Yes] button after checking the connection Clicking the [Yes] button after checking the voltage of
of external power supply advances to “5.6 Selection power supply advances to “5.6 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 “5.5 Selection Menu.” ton to return to “5.5 Selection Menu.”
Clicking the [Help] button will display the message Clicking the [Help] button will display the message
shown below. shown below.
The procedure that can be continued depends on where the communication error was generated.
Selection Item Descriptions
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.
Switch Confirmation screen for “Continue the procedure from confirmation process after reflashing.”
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-169
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.
Incorrect pass- Password for compul- Enter the correct password for
word for com- sory reflash is wrong. compulsory reflash.
pulsory
reflashing
7.3 Connection Confirmation Errors (for Sections 2.3, 3.3, 4.3, 5.3)
This message
appears to confirm
deletion when the
[No] button of the —
above message box
is clicked.
Electronic Control Fuel Injection System (Common Rail Type) 1E-171
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.
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.
Communica- Parts Number trans- Click the [OK] button to exit the
tion with the mission failure process, and then check the
selector selector.
Execution confirma-
tion of integrated con-
firmation process if
clicking the [Yes] in —
the massage above.
7.6 New ECM Parts Number Search Screen (2.9, 4.19) Errors
Campaign Campaign log file out- Check the HDD has enough
put error free space, and perform the
process again.
Others
Type Code Message Description
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.
This ECM needs compulsory reflash.
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.
1E-184 Electronic Control Fuel Injection System (Common Rail Type)
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-185
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
3
1
TSWG0050
Name
1. Breaker box 3. ECM
2. Adapter harness 4. To machine-side harness
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-187
TSWG0053
Name
1. Breaker box
2. ECM
3. Digital multimeter
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.
1E-188 Electronic Control Fuel Injection System (Common Rail Type)
Correction
Engine coolant temperature correction ECT sensor input
Barometric Pressure
Fuel temperature boost pressure correction
Correction between cylinders
Q-key correction
QR correction *
PCV opening
time determination Injector coil energizing time
Timing determination
Common rail
Injector coil
PCV
Injector
Supply pump
Fuel tank
TSWG0003
Electronic Control Fuel Injection System (Common Rail Type) 1E-189
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,
30
System realization engine speed
TSWG0175
(226 )
100%
About high-altitude correction
ECM calculates the current altitude based on the baro-
Fuel fiow
(221 )
Engine coolant temperature
TSWG0169
1E-190 Electronic Control Fuel Injection System (Common Rail Type)
Table of Input/Output
TSWG0001
Supply pump
Injector
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.
1E-192 Electronic Control Fuel Injection System (Common Rail Type)
TSWG0143
Name
1. Common rail 5. Pre-filter
2. Fuel filter 6. Feed pump
3. Injector 7. Supply pump
4. Fuel tank
No idle EGR
Engine speed
TSWG0174
EGR valve
Intake air
Intake air temperature sensor
Engine speed
ECT sensor
Engine load
TSWG0005
1E-194 Electronic Control Fuel Injection System (Common Rail Type)
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.
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
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.
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.
1E-196 Electronic Control Fuel Injection System (Common Rail Type)
Glow relay
Glow plug
QOS indicator lamp
LCD or Lamp) Engine coolant temperature sensor
TSWG0007
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.
Removal of ECM
1. Turn the key switch to OFF.
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”.
3. Leave as it is for 10 seconds.
Failure to perform the EGR valve position learning may
result in detection of DTC for EGR.
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
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
Electronic Control Fuel Injection System (Common Rail Type) 1E-199
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
1E-200 Electronic Control Fuel Injection System (Common Rail Type)
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
Electronic Control Fuel Injection System (Common Rail Type) 1E-201
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.
• If it is damaged, replace it as common rail ASM.
1E-202 Electronic Control Fuel Injection System (Common Rail Type)
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.
• If it is damaged, replace it as common rail ASM.
TSWG0017
TSWG0190
Electronic Control Fuel Injection System (Common Rail Type) 1E-203
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
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}
1E-204 Electronic Control Fuel Injection System (Common Rail Type)
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.
TSWG0067
Removal
• Disconnect the connector, and remove the 27 mm-
mounting bolt and sensor. (Lock position of the
connector is the lower side)
TSWG0020
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}
Electronic Control Fuel Injection System (Common Rail Type) 1E-205
Intake air temperature (IAT) sensor Removal
• Disconnect the connector, and remove the six 12
mm-mounting bolts and EGR valve.
Note:
Refer to the machine’s manual for the location of intake
air temperature (IAT) sensor.
TSWG0196
TSWG0149
Note:
Do not disassemble the EGR position sensor. If it is
faulty, replace it as EGR valve ASM.
1E-206 Electronic Control Fuel Injection System (Common Rail Type)
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-207
DLC (data link connector)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
TSWG0023
Note:
Refer to the machine’s manual for the locations of 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.
Note:
Refer to the machine’s manual for the locations of
memory clear switch.
Note:
Refer to the machine’s manual for the locations of
mode selector switch.
1E-208 Electronic Control Fuel Injection System (Common Rail Type)
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)*
(10A)*
46 94 U
EGR valve
Key switch (ST) 93 V
Battery position sensor
Starter relay 92 W
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
Electronic Control Fuel Injection System (Common Rail Type) 1E-209
Pin arrangement of engine control module (ECM)
TSWG0026
81-pin connector
40-pin connector
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
(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
1E-214 Electronic Control Fuel Injection System (Common Rail Type)
ON ON
START START
TSWG0028
Electronic Control Fuel Injection System (Common Rail Type) 1E-215
Starter for safety relay, glow circuit
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)
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
TSWG0029
(15A)*
A A
Machine trouble
diagnosis monitor
Machine
control unit
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
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)
TSWG0030
Electronic Control Fuel Injection System (Common Rail Type) 1E-217
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
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
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
TSWG0031
Electronic Control Fuel Injection System (Common Rail Type) 1E-219
PCV circuit
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)
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
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
2 E-98 1 E-98
Engine
coolant
temperature
Fuel temperature sensor sensor
Engine oil
pressure sensor
CKP sensor A
Vehicle A
speed sensor
1E-220 Electronic Control Fuel Injection System (Common Rail Type)
(*: 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
TSWG0034
Electronic Control Fuel Injection System (Common Rail Type) 1E-221
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
0.5 0.5
G sensor, common rail pressure sensor, EGR circuit
W U
EGR valve
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
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
TSWG0036
Electronic Control Fuel Injection System (Common Rail Type) 1E-223
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
1E-224 Electronic Control Fuel Injection System (Common Rail Type)
Engine control
module (ECM)
Idling selector Idle up Idle down Mode map Mode map Mode map
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)
switch signal switch signal switch signal switch 0 signal switch 1 signal switch 2 signal
TSWG0037
Electronic Control Fuel Injection System (Common Rail Type) 1E-225
Memory clear switch, engine stop switch circuit
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)
(15A)*
Key switch (ON)
Engine control module (ECM)
control unit
Machine
E-57
18
E-57
CAN LOW
37
E-57
47
E-57
32
B
B
TSWG0038
1E-226 Electronic Control Fuel Injection System (Common Rail Type)
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 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
Electronic Control Fuel Injection System (Common Rail Type) 1E-227
1E-228 Electronic Control Fuel Injection System (Common Rail Type)
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 —
Electronic Control Fuel Injection System (Common Rail Type) 1E-229
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 —
4 Injector power supply 1
2 OS — INJ1 signal/Injector #1
5 OS — INJ3 signal/Injector #3
3 Injector power supply 1
6 OS — INJ2 signal/Injector #5
4 Injector power supply 2
7 OS — INJ4 signal/Injector #6
5 —
8 OS — INJ1 signal/Injector #1
6 OS — INJ3 signal/Injector #3
9 —
7 OS — INJ5 signal/Injector #2
10 —
8 —
11 OS — INJ6 signal/Injector #4
12 OS — INJ7 signal/Injector #2
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
1E-230 Electronic Control Fuel Injection System (Common Rail Type)
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
Electronic Control Fuel Injection System (Common Rail Type) 1E-231
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
1 2 3
E-76
003-501
E-80
E-93
E-98
E-56
Engine harness side (male terminal)
(Dark gray)
Machine harness side (female terminal)
1E-232 Electronic Control Fuel Injection System (Common Rail Type)
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
H-1
000-009
E-114 (Silver)
FB-124
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
H-94
H-94
H-94
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.
Electronic Control Fuel Injection System (Common Rail Type) 1E-235
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.
(15A)*
A A
Meter
Machine
trouble
diagnosis
monitor
Diagnosis Engine oil QOS indicator Boost Tachometer
lamp pressure lamp lamp temperature
lamp
Machine
control
unit
TSWG0075
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
TSWG0074
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
TSWG0162
Name
1. Battery cable 2. Power socket cable (AC/DC adapter)
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
TSWG0074
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
(100A)*
Starter
B
Battery B
Generator
(15A)*
(60A)*
(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
TSWG0072
1E-250 Electronic Control Fuel Injection System (Common Rail Type)
Starter safety relay control
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)
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
TSWG0073
Name
1. Breaker box
2. DMM
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”
1E-254 Electronic Control Fuel Injection System (Common Rail Type)
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
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
Engine
control
module
(ECM)
TSWG0077
TSWG0143
Name
1. Common rail 5. Pre-filter
2. Fuel filter 6. Feed pump
3. Injector 7. Supply pump
4. Fuel tank
TSWG0168
Name
1. Reed valve
2. EGR valve
3. Exhaust side
4. Intake side
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
W U
EGR valve
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.
TSWG0150
EGR hysteresis
ON
OFF
60
(140 F)
TSWG0206
Electronic Control Fuel Injection System (Common Rail Type) 1E-265
QOS system check
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)
(100A)*
Starter
B
Battery B
Generator
(15A)*
(60A)*
(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
TSWG0072
1E-266 Electronic Control Fuel Injection System (Common Rail Type)
(15A)*
A A
Meter
Machine
trouble
diagnosis
monitor
Diagnosis Engine oil QOS indicator Boost Tachometer
lamp pressure lamp lamp temperature
lamp
Machine
control
unit
TSWG0075
Does the QOS indicator lamp come on? Go to Step 12. Go to Step 8.
1. Turn the key switch to “OFF”.
2. Remove the QOS indicator lamp.
8 3. Check the QOS indicator lamp for blow out. —
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.
1 2 3
ON
Back-up
Key ON mode
switch
and OFF
Engine
run OFF
TSWG0166
Name
1. DTC is detected.
ON 2. Returned to normal.
Diag
lamp
OFF
*3
When the DTC has recovered to normal in the ignition
cycle that the DTC is detected, the back-up mode will
ON be recovered normally, but the diagnosis lamp does not
Back-up
mode go off.
OFF
1 2
TSWG0165
Name Key
switch
ON
3. Returned to normal.
*2 ON
Diag
When the DTC has recovered to normal condition in lamp
the ignition cycle that the DTC is detected, the diagno- OFF
sis lamp and back up mode will also be recovered.
ON
Back-up
mode
OFF
TSWG0207
Name
1. DTC is detected.
2. Returned to normal.
Electronic Control Fuel Injection System (Common Rail Type) 1E-283
DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage)
TSWG0143
Name
1. Common rail 5. Pre-filter
2. Fuel filter 6. Feed pump
3. Injector 7. Supply pump
4. Fuel tank
1E-284 Electronic Control Fuel Injection System (Common Rail Type)
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
W U
EGR valve
TSWG0080
Diagnostic aid
presure
3 2 1
TSWG0055
Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply
(V)
4.2
0 200(29008)
MPa(psi)
TSWG0201
1E-288 Electronic Control Fuel Injection System (Common Rail Type)
DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in
supply pump)
TSWG0143
Name
1. Common rail 5. Pre-filter
2. Fuel filter 6. Feed pump
3. Injector 7. Supply pump
4. Fuel tank
Electronic Control Fuel Injection System (Common Rail Type) 1E-289
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
W U
EGR valve
TSWG0080
3 2 1
2 1
TSWG0055 TSWG0197
Name Name
1. Power supply 1. Coupling connector between engine — the
2. Signal machine
3. GND 2. Machine harness
3. Sensor connector
4. Engine harness
Characteristics of common rail pressure
sensor 1. Disconnect the coupling connector, and check the
sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
(V) the wiring of sensor connector.
4.2 3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the har-
ness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
0 200(29008)
MPa(psi)
TSWG0201
Electronic Control Fuel Injection System (Common Rail Type) 1E-293
DTC: P0091 (Flash code 247) PCV circuit fault (PCV1 open circuit or GND short circuit)
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)
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
Engine
control
module
(ECM)
TSWG0077
Is the “PCV F/B” less than the specified value? Go to Step 4. Go to Step 5.
1. Check for followings in the circuit between
PCV and ECM using breaker box or DMM.
Refer to 1E-297, “Breaker box inspection pro-
cedure, DTC: P0091 (Flash code 247) PCV
circuit fault (PCV1 open circuit or GND short
circuit), List of Diagnostic Trouble Codes”.
Note:
If breaker box is not available, refer to 1E-298,
“On-board check procedure for sensors, DTC:
4 P0091 (Flash code 247) PCV circuit fault (PCV1 —
open circuit or GND short circuit), List of Diagnostic
Trouble Codes”.
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace as
required.
1 2
TSWG0010
Electronic Control Fuel Injection System (Common Rail Type) 1E-297
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. PCV-HI
2. PCV-LO
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
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
Engine
control
module
(ECM)
TSWG0077
TSWG0010
Name
1. PCV #1
2. PCV #2
Name
1. Breaker box
2. DMM
Name
1. PCV-HI
2. PCV-LO
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
A A Engine control
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
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
TSWG0081
(V)
2.279198
1 2 3
1.009671
TSWG0205
TSWG0058
Breaker box inspection procedure
Name
1. Power supply Perform the inspection in the following procedure if
2. GND there is such an instruction to use breaker box in the
3. Signal step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
A A Engine control
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
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
TSWG0081
About barometric pressure sensor Tech2 and scan tools with KW communication can dis-
play both physical value and voltage.
(V)
2.279198
1 2 3
1.009671
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 1. Disconnect the coupling connector, and check the
sensor from engine harness connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Electronic Control Fuel Injection System (Common Rail Type) 1E-317
DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND
short, short circuit)
A A Engine control
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
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
TSWG0081
(V)
4.8691
0.1797
-40 120
(-40) (248) F
TSWG0180
1000
100
10
Resistance
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
1E-322 Electronic Control Fuel Injection System (Common Rail Type)
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
On-board check procedure for sensors 2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
A A Engine control
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
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
TSWG0081
(V)
4.8691
Name
1. Signal
2. GND
0.1797
Characteristics of intake air temperature
sensor -40 120
(-40) (248) F
The output voltage of IAT sensor changes according to TSWG0180
the intake air.
1000
100
10
Resistance
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
1E-330 Electronic Control Fuel Injection System (Common Rail Type)
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
TSWG0197
Electronic Control Fuel Injection System (Common Rail Type) 1E-331
DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault,
GND short, short circuit)
Engine control
module (ECM)
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
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
2 1
1 2 3
TSWG0061
Breaker box inspection procedure
Name
1. Sensor ground (for engine control) Perform the inspection in the following procedure if
2. Sensor signal (for engine control) there is such an instruction to use breaker box in the
3. Sensor signal (for meter) step. After inspection, return to the diagnostic step.
(V) Name
1. Breaker box
4.7441 2. DMM
0.2129
-40 120
(-40) (248) F
TSWG0181
1E-336 Electronic Control Fuel Injection System (Common Rail Type)
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
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
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
About ECT sensor Tech2 and scan tools with KW communication can dis-
play both physical value and voltage.
2 1
(V)
4.7441
1 2 3
0.2129
-40 120
(-40) (248) F
TSWG0061
TSWG0181
Name
1. Sensor ground (for engine control)
2. Sensor signal (for engine control)
3. Sensor signal (for meter)
Name
Breaker box inspection procedure 1. Breaker box
Perform the inspection in the following procedure if 2. DMM
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal
checked method value value
6, 17 Short circuit to Voltage mea- • Disconnect the 84 – Ground 0V 18V or more
power supply surement sensor connector.
circuit • Key switch “ON”
7, 18 Open circuit/ Resistance • Disconnect the 84 – Sensor connector 100Ω or less 10 MΩ or
high resistance measurement sensor connector. signal terminal more
• Key switch “OFF”
8, 19 Open circuit/ Resistance • Disconnect the 79 – Sensor connector 100Ω or less 10 MΩ or
high resistance measurement sensor connector. ground terminal more
• Key switch “OFF”
TSWG0197
1E-344 Electronic Control Fuel Injection System (Common Rail Type)
DTC: P0182 (Flash code 211) Fuel temperature sensor fault (low voltage fault, GND short)
(*: Specifications vary depending on each machine. Refer to the machine’s manual.)
Engine control
module (ECM)
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
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
Characteristics of FT sensor
The output voltage of FT sensor changes according to
the fuel temperature. The scan tool with CAN commu-
nication displays a fixed value when the value exceeds
the threshold voltage. Therefore, judge as it is more
than the threshold value if the value of −30°C (−22°F)
or 120°C (248°F) is not changed.
When error occurs, error value (214°C {419°F}) is dis-
played.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
Tech2 and scan tools with KW communication can dis-
play both physical value and voltage.
1E-348 Electronic Control Fuel Injection System (Common Rail Type)
Breaker box inspection procedure
Perform the inspection in the following procedure if
(V) there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
4.5195
0.1973
-30 120
(-22) (248) F
TSWG0203
25
Name
1. Breaker box
20 2. DMM
15
10
-30 0 30 60 90 120
(-22) (32) (86) (140) (194) (248) F
TSWG0210
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
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
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
25
20
15
10
-30 0 30 60 90 120
(-22) (32) (86) (140) (194) (248) F
TSWG0210
Characteristics of FT sensor
The output voltage of FT sensor changes according to
the fuel temperature. The scan tool with CAN commu-
nication displays a fixed value when the value exceeds
the threshold voltage.
Therefore, judge as it is more than the threshold value
if the value of −30°C (−22°F) or 120°C (248°F) is not
changed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
Tech2 and scan tools with KW communication can dis-
play both physical value and voltage.
(V)
4.5195 Name
1. Breaker box
2. DMM
0.1973
-30 120
(-22) (248) F
TSWG0203
Electronic Control Fuel Injection System (Common Rail Type) 1E-357
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
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
W U
EGR valve
TSWG0080
3 2 1
TSWG0055
Name
1. GND
2. Signal
3. Power supply Name
1. Breaker box
2. DMM
Characteristics of common rail pressure
sensor
(V)
4.2
0 200(29008)
MPa(psi)
TSWG0201
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
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
W U
EGR valve
TSWG0080
(V)
4.2
3 2 1
1
0 200(29008)
TSWG0055 MPa(psi)
Name TSWG0201
1. GND
2. Signal
3. Power supply
Electronic Control Fuel Injection System (Common Rail Type) 1E-369
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
TSWG0197
1E-370 Electronic Control Fuel Injection System (Common Rail Type)
DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Description of circuit
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and ener-
gizes the pressurized voltage (more than 100 V) to the
injector. For injector operation, the voltage applied to
the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
Electronic Control Fuel Injection System (Common Rail Type) 1E-371
Cylinder No. and injection order Action taken when DTC is set
• Trouble is displayed on the monitor of the
machine or diagnosis lamp comes on.
8
1
2 Back-up mode
• Specified back-up value
3
6
The conditions to clear the MIL/DTC
• The present trouble turns to history trouble when
the condition is out of the range from DTC set con-
TSWG0157
dition (recovery from failure).
Name
1. Cylinder No. 1 • The diagnosis lamp will go off after the code turns
2. Cylinder No. 2 to history trouble and the key switch is turned
3. Cylinder No. 3 “OFF” then “ON” again.
4. Cylinder No. 4 • Using the scan tool, or memory clear switch and
5. Cylinder No. 5 diagnostic switch operation enables to clear DTCs.
6. Cylinder No. 6
7. Cylinder block Diagnostic aid
8. Engine front If the intermittent trouble is suspected, followings may
be the cause.
Fuel injection is performed to each cylinder in the order • Improper connection of harness connector
of 1 — 5 — 3 — 6 — 2 — 4. • Defective harness routing
• Worn harness cladding
Main trouble symptom
• Wire disconnection inside harness cladding
• Unstable idling Following inspections are necessary to detect these
• Output shortage causes.
• Improper connection of harness connector and
Preconditions when DTC is set ECM connector
• Main relay power supply voltage is 16V or more. – Poor connection of terminal from connector
• 70 rpm or more – Unmatched terminals are fitted.
• DTC P0611, P1261, or P0201 is not detected. – Damage of connector lock
– Poor contact between terminal and wire
DTC set condition
• Damaged harness
• Open/short circuit is detected in No. 1 cylinder – Visually check the harness for damage.
injector drive circuit.
– Check the relevant items on the scan tool data
• No. 1 cylinder injector monitor input signal does display while moving the connector and the har-
not exist for 2.4 seconds or more. ness which are related to the sensor. The varia-
tion of the display indicates the faulty part.
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Description of circuit
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and ener-
gizes the pressurized voltage (more than 100 V) to the
injector. For injector operation, the voltage applied to
the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
1E-376 Electronic Control Fuel Injection System (Common Rail Type)
Cylinder No. and injection order Action taken when DTC is set
• Trouble is displayed on the monitor of the
machine or diagnosis lamp comes on.
8
1
2 Back-up mode
• Specified back-up value
3
6
The conditions to clear the MIL/DTC
• The present trouble turns to history trouble when
the condition is out of the range from DTC set con-
TSWG0157
dition (recovery from failure).
Name
1. Cylinder No. 1 • The diagnosis lamp will go off after the code turns
2. Cylinder No. 2 to history trouble and the key switch is turned
3. Cylinder No. 3 “OFF” then “ON” again.
4. Cylinder No. 4 • Using the scan tool, or memory clear switch and
5. Cylinder No. 5 diagnostic switch operation enables to clear DTCs.
6. Cylinder No. 6
7. Cylinder block Diagnostic aid
8. Engine front If the intermittent trouble is suspected, followings may
be the cause.
Fuel injection is performed to each cylinder in the order • Improper connection of harness connector
of 1 — 5 — 3 — 6 — 2 — 4. • Defective harness routing
• Worn harness cladding
Main trouble symptom
• Wire disconnection inside harness cladding
• Unstable idling Following inspections are necessary to detect these
• Output shortage causes.
• Improper connection of harness connector and
Preconditions when DTC is set ECM connector
• Main relay power supply voltage is 16V or more. – Poor connection of terminal from connector
• 70 rpm or more – Unmatched terminals are fitted.
• DTC P0611, P1261 or P0202 is not detected. – Damage of connector lock
– Poor contact between terminal and wire
DTC set condition
• Damaged harness
• Open/short circuit is detected in No. 2 cylinder – Visually check the harness for damage.
injector drive circuit.
– Check the relevant items on the scan tool data
• No. 2 cylinder injector monitor input signal does display while moving the connector and the har-
not exist for 2.4 seconds or more. ness which are related to the sensor. The varia-
tion of the display indicates the faulty part.
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Description of circuit
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and ener-
gizes the pressurized voltage (more than 100 V) to the
injector. For injector operation, the voltage applied to
the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
Electronic Control Fuel Injection System (Common Rail Type) 1E-381
Cylinder No. and injection order Action taken when DTC is set
• Trouble is displayed on the monitor of the
machine or diagnosis lamp comes on.
8
1
2 Back-up mode
• Specified back-up value
3
6
The conditions to clear the MIL/DTC
• The present trouble turns to history trouble when
the condition is out of the range from DTC set con-
TSWG0157
dition (recovery from failure).
Name
1. Cylinder No. 1 • The diagnosis lamp will go off after the code turns
2. Cylinder No. 2 to history trouble and the key switch is turned
3. Cylinder No. 3 “OFF” then “ON” again.
4. Cylinder No. 4 • Using the scan tool, or memory clear switch and
5. Cylinder No. 5 diagnostic switch operation enables to clear DTCs.
6. Cylinder No. 6
7. Cylinder block Diagnostic aid
8. Engine front If the intermittent trouble is suspected, followings may
be the cause.
Fuel injection is performed to each cylinder in the order • Improper connection of harness connector
of 1 — 5 — 3 — 6 — 2 — 4. • Defective harness routing
• Worn harness cladding
Main trouble symptom
• Wire disconnection inside harness cladding
• Unstable idling Following inspections are necessary to detect these
• Output shortage causes.
• Improper connection of harness connector and
Preconditions when DTC is set ECM connector
• Main relay power supply voltage is 16V or more. – Poor connection of terminal from connector
• 70 rpm or more – Unmatched terminals are fitted.
• DTC P0611, P1261, or P0203 is not detected. – Damage of connector lock
– Poor contact between terminal and wire
DTC set condition
• Damaged harness
• Open/short circuit is detected in No. 3 cylinder – Visually check the harness for damage.
injector drive circuit.
– Check the relevant items on the scan tool data
• No. 3 cylinder injector monitor input signal does display while moving the connector and the har-
not exist for 2.4 seconds or more. ness which are related to the sensor. The varia-
tion of the display indicates the faulty part.
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Description of circuit
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and ener-
gizes the pressurized voltage (more than 100 V) to the
injector. For injector operation, the voltage applied to
the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
1E-386 Electronic Control Fuel Injection System (Common Rail Type)
Cylinder No. and injection order Action taken when DTC is set
• Trouble is displayed on the monitor of the
machine or diagnosis lamp comes on.
8
1
2 Back-up mode
• Specified back-up value
3
6
The conditions to clear the MIL/DTC
• The present trouble turns to history trouble when
the condition is out of the range from DTC set con-
TSWG0157
dition (recovery from failure).
Name
1. Cylinder No. 1 • The diagnosis lamp will go off after the code turns
2. Cylinder No. 2 to history trouble and the key switch is turned
3. Cylinder No. 3 “OFF” then “ON” again.
4. Cylinder No. 4 • Using the scan tool, or memory clear switch and
5. Cylinder No. 5 diagnostic switch operation enables to clear DTCs.
6. Cylinder No. 6
7. Cylinder block Diagnostic aid
8. Engine front If the intermittent trouble is suspected, followings may
be the cause.
Fuel injection is performed to each cylinder in the order • Improper connection of harness connector
of 1 — 5 — 3 — 6 — 2 — 4. • Defective harness routing
• Worn harness cladding
Main trouble symptom
• Wire disconnection inside harness cladding
• Unstable idling Following inspections are necessary to detect these
• Output shortage causes.
• Improper connection of harness connector and
Preconditions when DTC is set ECM connector
• Main relay power supply voltage is 16V or more. – Poor connection of terminal from connector
• 70 rpm or more – Unmatched terminals are fitted.
• DTC P0612, P1262, or P0204 is not detected. – Damage of connector lock
– Poor contact between terminal and wire
DTC set condition
• Damaged harness
• Open/short circuit is detected in No. 4 cylinder – Visually check the harness for damage.
injector drive circuit.
– Check the relevant items on the scan tool data
• No. 4 cylinder injector monitor input signal does display while moving the connector and the har-
not exist for 2.4 seconds or more. ness which are related to the sensor. The varia-
tion of the display indicates the faulty part.
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Description of circuit
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and ener-
gizes the pressurized voltage (more than 100 V) to the
injector. For injector operation, the voltage applied to
the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
Electronic Control Fuel Injection System (Common Rail Type) 1E-391
Cylinder No. and injection order Action taken when DTC is set
• Trouble is displayed on the monitor of the
machine or diagnosis lamp comes on.
8
1
2 Back-up mode
• Specified back-up value
3
6
The conditions to clear the MIL/DTC
• The present trouble turns to history trouble when
the condition is out of the range from DTC set con-
TSWG0157
dition (recovery from failure).
Name
1. Cylinder No. 1 • The diagnosis lamp will go off after the code turns
2. Cylinder No. 2 to history trouble and the key switch is turned
3. Cylinder No. 3 “OFF” then “ON” again.
4. Cylinder No. 4 • Using the scan tool, or memory clear switch and
5. Cylinder No. 5 diagnostic switch operation enables to clear DTCs.
6. Cylinder No. 6
7. Cylinder block Diagnostic aid
8. Engine front If the intermittent trouble is suspected, followings may
be the cause.
Fuel injection is performed to each cylinder in the order • Improper connection of harness connector
of 1 — 5 — 3 — 6 — 2 — 4. • Defective harness routing
• Worn harness cladding
Main trouble symptom
• Wire disconnection inside harness cladding
• Unstable idling Following inspections are necessary to detect these
• Output shortage causes.
• Improper connection of harness connector and
Preconditions when DTC is set ECM connector
• Main relay power supply voltage is 16V or more. – Poor connection of terminal from connector
• 70 rpm or more – Unmatched terminals are fitted.
• DTC P0612, P1262, or P0205 is not detected. – Damage of connector lock
– Poor contact between terminal and wire
DTC set condition
• Damaged harness
• Open/short circuit is detected in No. 5 cylinder – Visually check the harness for damage.
injector drive circuit.
– Check the relevant items on the scan tool data
• No. 5 cylinder injector monitor input signal does display while moving the connector and the har-
not exist for 2.4 seconds or more. ness which are related to the sensor. The varia-
tion of the display indicates the faulty part.
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Description of circuit
The injector performs fuel injection. The injector is
installed in the engine head. The engine control module
(ECM) controls the fuel injection amount and timing by
controlling the energizing time to the injector. Also, it
generates the voltage for injector operation and ener-
gizes the pressurized voltage (more than 100 V) to the
injector. For injector operation, the voltage applied to
the injector will be sent back the to the ECM through
injector as a signal, and the ECM controls this signal.
1E-396 Electronic Control Fuel Injection System (Common Rail Type)
Cylinder No. and injection order Action taken when DTC is set
• Trouble is displayed on the monitor of the
machine or diagnosis lamp comes on.
8
1
2 Back-up mode
• Specified back-up value
3
6
The conditions to clear the MIL/DTC
• The present trouble turns to history trouble when
the condition is out of the range from DTC set con-
TSWG0157
dition (recovery from failure).
Name
1. Cylinder No. 1 • The diagnosis lamp will go off after the code turns
2. Cylinder No. 2 to history trouble and the key switch is turned
3. Cylinder No. 3 “OFF” then “ON” again.
4. Cylinder No. 4 • Using the scan tool, or memory clear switch and
5. Cylinder No. 5 diagnostic switch operation enables to clear DTCs.
6. Cylinder No. 6
7. Cylinder block Diagnostic aid
8. Engine front If the intermittent trouble is suspected, followings may
be the cause.
Fuel injection is performed to each cylinder in the order • Improper connection of harness connector
of 1 — 5 — 3 — 6 — 2 — 4. • Defective harness routing
• Worn harness cladding
Main trouble symptom
• Wire disconnection inside harness cladding
• Unstable idling Following inspections are necessary to detect these
• Output shortage causes.
• Improper connection of harness connector and
Preconditions when DTC is set ECM connector
• Main relay power supply voltage is 16V or more. – Poor connection of terminal from connector
• 70 rpm or more – Unmatched terminals are fitted.
• DTC P0612, P1262, or P0206 is not detected. – Damage of connector lock
– Poor contact between terminal and wire
DTC set condition
• Damaged harness
• Open/short circuit is detected in No. 6 cylinder – Visually check the harness for damage.
injector drive circuit.
– Check the relevant items on the scan tool data
• No. 6 cylinder injector monitor input signal does display while moving the connector and the har-
not exist for 2.4 seconds or more. ness which are related to the sensor. The varia-
tion of the display indicates the faulty part.
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine
control
G sensor Common rail pressure module
signal sensor signal (ECM)
5V
CKP CKP
HIGH LOW
signal signal
98 E-56 101 E-56 100 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
0.75
L
0.75 B
CKP sensor
1 E-112 2 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSWG0070
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
TSWG0079
Description of circuit The ECM sets the DTC when the signal voltage from
The boost pressure sensor is installed to the intake the boost pressure sensor is less than the normal
manifold. The boost pressure sensor outputs the volt- range.
age corresponding to the internal pressure of the intake
manifold, and the ECM detects the boost by this signal. Main trouble symptom
The boost pressure sensor includes following circuits. Operationality is affected.
• 5-V power supply circuit
• Ground circuit
Preconditions when DTC is set
• Boost pressure sensor signal circuit • Key switch input voltage is 16V or more.
The ECM provides 5 V to the boost pressure sensor • DTC P1630 or P1634 is not detected.
through 5-V power supply circuit, and grounds to the
inside of the ECM through ground circuit. Also, the DTC set condition
boost pressure sensor outputs the signal voltage to the • Boost pressure sensor voltage is 0.1 V or less.
ECM through boost pressure sensor signal circuit. The
ECM detects a low boost condition (the engine load is
low) when the signal voltage from the boost pressure
sensor is low, and a high boost condition (the engine
load is high) when the signal voltage from the boost
pressure sensor is high.
Electronic Control Fuel Injection System (Common Rail Type) 1E-403
Action taken when DTC is set • Defective harness routing
• Trouble is displayed on the monitor of the • Worn harness cladding
machine or diagnosis lamp comes on. • Wire disconnection inside harness cladding
Following inspections are necessary to detect these
causes.
• Improper connection of harness connector and
Back-up mode ECM connector
• Boost pressure default setting (200 MPa {29008 – Poor connection of terminal from connector
psi}) – Unmatched terminals are fitted.
• Boost pressure correction/EGR stopped – Damage of connector lock
– Poor contact between terminal and wire
Recovery from failure
• Damaged harness
Refer to 1E-270, “List of Diagnostic Trouble Codes”
and “About recovery from failure” in this section for – Visually check the harness for damage.
recovery from failure. – Check the relevant items on the scan tool data
display while moving the connector and the har-
The conditions to clear the MIL/DTC ness which are related to the sensor. The varia-
tion of the display indicates the faulty part.
• The present trouble turns to history trouble when
the condition is out of the range from DTC set con-
Test description
dition (recovery from failure).
• The diagnosis lamp will go off after the code turns Numbers below indicate step numbers in the chart.
to history trouble and the key switch is turned 3. In the case of present trouble, the “MAP (manifold
“OFF” then “ON” again. absolute pressure) sensor” displays less than the
threshold value. If more than the specified value, iden-
• Using the scan tool, or memory clear switch and tify the cause by referring to “Diagnostic aid”.
diagnostic switch operation enables to clear DTCs. 5. If “MAP (manifold absolute pressure) sensor” dis-
plays more than the threshold value when terminals
Diagnostic aid between the boost pressure sensor connector are
If the intermittent trouble is suspected, followings may shorted, the circuit beyond the sensor is normal includ-
be the cause. ing ECM.
• Improper connection of harness connector
(V)
4.75026
3 2 1
0.100082
40(5802) 350(50763)
MPa(psi)
TSWG0063
TSWG0062
Breaker box inspection procedure
Name
1. Sensor ground Perform the inspection in the following procedure if
2. Sensor signal there is such an instruction to use breaker box in the
3. Sensor power supply step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
TSWG0079
(V)
4.75026
3 2 1
0.100082
40(5802) 350(50763)
MPa(psi)
TSWG0063
TSWG0062
Breaker box inspection procedure
Name
1. Sensor ground Perform the inspection in the following procedure if
2. Sensor signal there is such an instruction to use breaker box in the
3. Sensor power supply step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine
control
G sensor Common rail pressure module
signal sensor signal (ECM)
5V
CKP CKP
HIGH LOW
signal signal
98 E-56 101 E-56 100 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
0.75
L
0.75 B
CKP sensor
1 E-112 2 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSWG0070
TSHK0128
TSWG0064
Name
1. GND
2. Power supply
1E-420 Electronic Control Fuel Injection System (Common Rail Type)
About CKP sensor and G sensor signals 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.
TSWG0151
Name
1. CKP signal
2. G sensor signal
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine
control
G sensor Common rail pressure module
signal sensor signal (ECM)
5V
CKP CKP
HIGH LOW
signal signal
98 E-56 101 E-56 100 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
0.75
L
0.75 B
CKP sensor
1 E-112 2 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSWG0070
5 Note: —
If breaker box is not available, refer to 1E-426,
“On-board check procedure for sensors, DTC:
P0336 (Flash code 15) Crank sensor fault (signal
fault), List of Diagnostic Trouble Codes”.
2. If the trouble is detected, repair or replace as
required.
TSHK0128
TSWG0064
Name
1. GND
2. Power supply
1E-426 Electronic Control Fuel Injection System (Common Rail Type)
About CKP sensor and G sensor signals 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.
TSWG0151
Name
1. CKP signal
2. G sensor signal
Name
1. Breaker box
2. DMM
TSWG0197
Electronic Control Fuel Injection System (Common Rail Type) 1E-427
DTC: P0340 (Flash code 14) G sensor fault (no signal)
Engine
control
G sensor Common rail pressure module
signal sensor signal (ECM)
5V
CKP CKP
HIGH LOW
signal signal
98 E-56 101 E-56 100 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
0.75
L
0.75 B
CKP sensor
1 E-112 2 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSWG0070
1 2 3 2
TSWG0065 TSWG0151
Name Name
1. Signal 1. CKP signal
2. GND 2. G sensor signal
3. Power supply
TSWG0199
Name
1. G sensor
2. Pulser
Name
1. Breaker box
2. DMM
1E-432 Electronic Control Fuel Injection System (Common Rail Type)
On-board check procedure for sensors • If both steps 1 and 2 are faulty, repair the har-
ness. Check from step 1 again.
3 • If only step 1 is faulty, replace the sensor.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine
control
G sensor Common rail pressure module
signal sensor signal (ECM)
5V
CKP CKP
HIGH LOW
signal signal
98 E-56 101 E-56 100 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
0.75
L
0.75 B
CKP sensor
1 E-112 2 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSWG0070
About G sensor
2
1
15
1 2 3
TSWG0199
TSWG0065
Name
1. G sensor
Name
2. Pulser
1. Signal
2. GND
3. Power supply
Electronic Control Fuel Injection System (Common Rail Type) 1E-437
About CKP sensor and G sensor signals 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.
TSWG0151
Name
1. CKP signal
2. G sensor signal
Name
1. Breaker box
2. DMM
TSWG0197
1E-438 Electronic Control Fuel Injection System (Common Rail Type)
DTC: P0380 (Flash code 66) Glow relay circuit fault
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)
(100A)*
Starter
B
Battery B
Generator
(15A)*
(60A)*
(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
TSWG0072
Name
1. Breaker box
2. DMM
TSWG0197
Electronic Control Fuel Injection System (Common Rail Type) 1E-443
DTC: P0381 (Flash code 67) Glow plug lamp circuit fault
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)
(15A)*
A A
Meter
Machine
trouble
diagnosis
monitor
Diagnosis Engine oil QOS indicator Boost Tachometer
lamp pressure lamp lamp temperature
lamp
Machine
control
unit
TSWG0075
Does the QOS indicator lamp come on? Go to Step 13. Go to Step 8.
Check for installation condition of the meter, ECM
connector and coupling connector.
Name
1. Breaker box
2. DMM
Step Item to be Inspection Measuring condition Terminal No. Normal value Abnormal
checked method value
6 Short circuit to Resistance • Remove the meter 11 – Ground 10 MΩ or 10 MΩ or less
ground measurement connector. more
• Key switch “OFF”
7 Open circuit/ Lamp ON • Remove the ECM. Short the terminal Lamp ON Lamp OFF
high resistance • Key switch “ON” No. 11 with ground
circuit.
10 Open circuit/ Resistance • Remove the meter 11 – Meter connector 10 MΩ or less 10 MΩ or
high resistance measurement connector. QOS indicator lamp more
• Key switch “OFF” terminal
1E-448 Electronic Control Fuel Injection System (Common Rail Type)
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
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
W U
EGR valve
TSWG0080
TSWG0158
Name
Name 1. Breaker box
1. Position sensor power supply (5 V) 2. DMM
2. Position sensor signal W
3. Position sensor signal V
4. Position sensor signal U
5. Position sensor ground
6. Motor drive W
7. Motor drive V
8. Motor drive U
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
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
W U
EGR valve
TSWG0080
TSWG0158
1E-458 Electronic Control Fuel Injection System (Common Rail Type)
EGR valve check 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.
TSWG0150
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
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
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
(V)
4.85
1 2 3
0.496
0 1088.5(157.9)
kPa(psi)
TSWG0202
TSWG0164
Breaker box inspection procedure
Name
1. Sensor ground Perform the inspection in the following procedure if
2. Sensor signal there is such an instruction to use breaker box in the
3. Sensor power supply step. After inspection, return to the diagnostic step.
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
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
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
About engine oil pressure sensor The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
Tech2 and scan tools with KW communication can dis-
play both physical value and voltage.
(V)
4.85
1 2 3
0.496
TSWG0164
Name
1. Sensor ground 0 1088.5(157.9)
kPa(psi)
2. Sensor signal
TSWG0202
3. Sensor power supply
Name
1. Breaker box
2. DMM
TSWG0197
Electronic Control Fuel Injection System (Common Rail Type) 1E-473
DTC: P0601 (Flash code 53) ROM fault
Description of circuit Back-up mode
The internal part of the ECM consists of ROM, • Engine stopped
EEPROM, CPU, and Sub-CPU, which perform data
storage, data clear and various controls. Recovery from failure
The ECM sets the DTC when the ROM fault inside the
Refer to 1E-270, “List of Diagnostic Trouble Codes”
ECM is detected.
and “About recovery from failure” in this section for
recovery from failure.
Main trouble symptom
Engine stopped The conditions to clear the MIL/DTC
• The present trouble turns to history trouble when
DTC set condition the condition is out of the range from DTC set con-
• ROM fault is detected. dition (recovery from failure).
• Reflash failure • The diagnosis lamp will go off after the code turns
to history trouble and the key switch is turned
Action taken when DTC is set “OFF” then “ON” again.
• Trouble is displayed on the monitor of the • Using the scan tool, or memory clear switch and
machine or diagnosis lamp comes on. diagnostic switch operation enables to clear DTCs.
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
TSWG0074
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
TSWG0074
(100A)*
Starter
B
Battery B
Generator
(15A)*
(60A)*
(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
TSWG0072
Is the “Starter switch (ST)” displayed “ON”? Go to Step 11. Go to Step 10.
1E-490 Electronic Control Fuel Injection System (Common Rail Type)
Name
1. Breaker box
2. DMM
1E-492 Electronic Control Fuel Injection System (Common Rail Type)
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
(15A)*
A A
Meter
Machine
trouble
diagnosis
monitor
Diagnosis Engine oil QOS indicator Boost Tachometer
lamp pressure lamp lamp temperature
lamp
Machine
control
unit
TSWG0075
Name
1. Breaker box
2. DMM
10 Open circuit/ Resistance • Remove the meter 6 – Meter connector 100Ω or less 10 MΩ or
high resistance measurement connector. diagnosis lamp termi- more
• Key switch “OFF” nal
1E-498 Electronic Control Fuel Injection System (Common Rail Type)
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
TSWG0143
Name
1. Common rail 5. Pre-filter
2. Fuel filter 6. Feed pump
3. Injector 7. Supply pump
4. Fuel tank
1E-500 Electronic Control Fuel Injection System (Common Rail Type)
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
W U
EGR valve
TSWG0080
3 4
Commonrail
pressure
2
5
10MPa
P1093
10MPa
P1094
TSWG0184
TSWG0159
Action taken when DTC is set
Name
1. Fuel pump strainer • Trouble is displayed on the monitor of the
2. Pre-fuel filter machine or diagnosis lamp comes on.
3. Main fuel filter
4. Electromagnetic pump filter
5. Gauze filter
Back-up mode
Filter clogging in the fuel system may establish the • Limited injection amount 3 (multi-injection stopped)
DTC set condition. Check as required. target RP upper limit (80 MPa {11603 psi})
(V)
4.2
3 2 1
1
0 200(29008)
TSWG0055 MPa(psi)
Name TSWG0201
1. Sensor ground
2. Sensor signal
3. Sensor power supply
1E-506 Electronic Control Fuel Injection System (Common Rail Type)
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
On-board check procedure for sensors 2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
TSWG0143
Name
1. Common rail 5. Pre-filter
2. Fuel filter 6. Feed pump
3. Injector 7. Supply pump
4. Fuel tank
1E-508 Electronic Control Fuel Injection System (Common Rail Type)
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
W U
EGR valve
TSWG0080
Description of circuit
The supply pump sucks fuel from the fuel tank using
the trochoid-type feed pump located inside of the sup-
ply pump. The sucked fuel is sent through the PCV to
the two plungers located inside the supply pump, and is
pressurized and sent to the common rail. The PCV
opening angle controls the fuel flow; if the PCV drive
duty is large, the PCV opening angle becomes small
resulting in less fuel flow. The ECM drives the PCV by
calculating the target common rail pressure, target fuel
flow, etc. based on the information from each sensor.
The ECM sets the DTC when the actual fuel flow is
lower than the target fuel flow, or when the common rail
pressure drops sharply.
3 4
Commonrail
pressure
2
5
10MPa
P1093
10MPa
P1094
TSWG0184
TSWG0159
Action taken when DTC is set
Name
1. Fuel pump strainer • Trouble is displayed on the monitor of the
2. Pre-fuel filter machine or diagnosis lamp comes on.
3. Main fuel filter
4. Electromagnetic pump filter
5. Gauze filter
Back-up mode
Filter clogging in the fuel system may establish the • Limited injection amount 3 (multi-injection stopped)
DTC set condition. Check as required. target RP upper limit (80 MPa {11603 psi})
(V)
4.2
3 2 1
1
0 200(29008)
TSWG0055 MPa(psi)
Name TSWG0201
1. Sensor ground
2. Sensor signal
3. Sensor power supply
1E-514 Electronic Control Fuel Injection System (Common Rail Type)
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
On-board check procedure for sensors 2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
TSWG0143
Name
1. Common rail 5. Pre-filter
2. Fuel filter 6. Feed pump
3. Injector electromagnetic pump 7. Supply pump
4. Fuel tank
1E-516 Electronic Control Fuel Injection System (Common Rail Type)
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
W U
EGR valve
TSWG0080
Description of circuit
The supply pump sucks fuel from the fuel tank using
the trochoid-type feed pump located inside of the sup-
ply pump. The sucked fuel is sent through the PCV to
the two plungers located inside the supply pump, and is
pressurized and sent to the common rail. The PCV
opening angle controls the fuel flow; if the PCV drive
duty is large, the PCV opening angle becomes small
resulting in less fuel flow. The ECM drives the PCV by
calculating the target common rail pressure, target fuel
flow, etc. based on the information from each sensor.
The ECM sets the DTC when the common rail pressure
increases to certain level then lowers sharply, as it rec-
ognizes that the pressure limiter is activated.
Common rail
3 4
presure
T>1sec=P1095
200 MPa
2 (29008psi)
155 MPa T
5
(22481psi)
150 MPa
(21756psi)
T
T>5sec=P0088
TSWG0179
TSWG0159
Action taken when DTC is set
Name
1. Fuel pump strainer • Trouble is displayed on the monitor of the
2. Pre-fuel Filter machine or diagnosis lamp comes on.
3. Main fuel filter
4. Electromagnetic pump filter
5. Gauze filter
Back-up mode
Filter clogging in the fuel system may establish the • Limited injection amount 1
DTC set condition. Check as required. • Output goes down to about 50% since fuel flow is
limited.
Preconditions when DTC is set
• Key switch input voltage is 16V or more. Recovery from failure
• DTC P1095, P0192, P0193, P1630, or P1635 is Refer to 1E-270, “List of Diagnostic Trouble Codes”
not detected. and “About recovery from failure” in this section for
recovery from failure.
• 50 rpm or more
The conditions to clear the MIL/DTC
DTC set condition
• The present trouble turns to history trouble when
• When pressure limiter is opened.
the condition is out of the range from DTC set con-
• When common rail pressure is more than 200 MPa dition (recovery from failure).
(29008 psi) for 1 second or more.
• The diagnosis lamp will go off after the code turns
• DTC set condition in the case of high common rail to history trouble and the key switch is turned
pressure is described below. Only P1095 is “OFF” then “ON” again.
detected if the fuel pressure overshoots due to
• Using the scan tool, or memory clear switch and
entry of air.
diagnostic switch operation enables to clear DTCs.
Diagnostic aid
Followings are suspected as the cause.
• Air mixed in the high-pressure fuel pipe.
• Injector internal trouble
• Supply pump internal trouble
• Fuel system pipe fault (clogging etc.)
• Fuel filter fault (temporary clogging due to waxing
at low temperatures, improper tightening of filter
cartridge, etc.)
1E-518 Electronic Control Fuel Injection System (Common Rail Type)
• Fuel tank fault (temporary clogging, air mixed due • Running out of fuel
to fuel shortage, air mixed due to modified fuel
pipe for additional tank etc.) Test description
• Pressure limiter trouble (operation under specified Numbers below indicate step numbers in the chart.
pressure, degradation of sealability) 8. If the “Common rail pressure sensor” displays more
• ECM trouble than the specified value when the common rail pres-
• Common rail pressure sensor trouble sure sensor connector is removed, the circuit beyond
the sensor is normal including ECM.
(V)
4.2
3 2 1
1
0 200(29008)
TSWG0055 MPa(psi)
Name TSWG0201
1. Sensor ground
2. Sensor signal
3. Sensor power supply
Electronic Control Fuel Injection System (Common Rail Type) 1E-523
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
On-board check procedure for sensors 2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
TSWG0079
About boost temperature sensor The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
Tech2 and scan tools with KW communication can dis-
play both physical value and voltage.
(V)
4.9824
1.1719
Name
1. Signal -40 120
2. GND (-40) (248) F
TSWG0204
1000
100
10
Resistance
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
TSWG0079
About boost temperature sensor Tech2 and scan tools with KW communication can dis-
play both physical value and voltage.
(V)
4.9824
1.1719
-40 120
(-40) (248) F
TSWG0204
Name
1. Signal
2. GND
1000
100
10
Resistance
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
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
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
Description of circuit
The engine coolant temperature (ECT) sensor is
installed in the thermostat housing. The ETC sensor is
the thermistor-type sensor, and the value of resistance
and output voltage change according to the engine
coolant temperature. As the engine coolant tempera-
ture increases, the resistance becomes small, and the 100%
(226 )
The ECM sets the DTC when it judges that the engine (248 )
coolant temperature exceed certain level based on the
signal from the ECT sensor.
5 Note: —
If breaker box is not available, refer to 1E-542,
“On-board check procedure for sensors, DTC:
P1173 (Flash code 542) Overheat, List of Diagnos-
tic Trouble Codes”.
2. If the trouble is detected, repair as required.
TSWG0061
Name
1. Sensor ground (for engine control)
2. Sensor signal (for engine control)
3. Sensor signal (for meter)
1E-542 Electronic Control Fuel Injection System (Common Rail Type)
(V)
4.7441
0.2129
-40 120
(-40) (248) F
TSWG0181
Name
Breaker box inspection procedure 1. Breaker box
Perform the inspection in the following procedure if 2. DMM
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal
checked method value value
5 Short circuit to Voltage mea- • Disconnect the 84 – Ground 0V 1V or more
other signal cir- surement sensor connector.
cuit • Key switch “ON”
On-board check procedure for sensors 2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
(15A)*
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
TSWG0082
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 1. Disconnect the coupling connector, and check the
sensor from engine harness connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Electronic Control Fuel Injection System (Common Rail Type) 1E-547
DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Is the resistance less than the specified value? Go to Step 6. Go to Step 22.
Check for installation condition of the injector har-
ness connector, ECM connector and coupling con-
nector.
4 1. Check for play or looseness in the connection. —
2. If the trouble is detected, repair as required.
Is the resistance more than the specified value? Go to Step 8. Go to Step 10.
1. Turn the key switch to “OFF”.
2. Remove the ECM-side harness connector
from the coupling connector (H-94).
8 3. Measure the resistance between the No. 3 cyl- 10 MΩ
inder injector drive circuit (H94 male-side No.
6) and the ground.
Is the resistance more than the specified value? Go to Step 12. Go to Step 11.
1. Check the No. 1 cylinder injector drive circuit
between ECM and coupling connector (H-94)
for ground short circuit using breaker box or
DMM.
Refer to 1E-554, “Breaker box inspection pro-
cedure, DTC: P1261 (Flash code 158) Injec-
tion nozzle common 1 drive system fault, List
of Diagnostic Trouble Codes”.
9 Note: —
If breaker box is not available, refer to 1E-555,
“On-board check procedure for sensors, DTC:
P1261 (Flash code 158) Injection nozzle common 1
drive system fault, List of Diagnostic Trouble
Codes”.
2. If the trouble is detected, repair as required.
Is the resistance more than the specified value? Go to Step 14. Go to Step 23.
1. Turn the key switch to “OFF”.
2. Remove the injector-side harness connector
from the coupling connector (H-94).
3. Connect the DMM between the No. 1 cylinder
14 injector drive circuit (H94 female-side No. 2) 0V
and the ground.
4. Turn the key switch to “ON”.
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 3. Check the harness from coupling connector for
open circuit.
3 • If both steps 1 and 2 are faulty, repair the har-
ness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31
3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94
1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W
116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56
Is the resistance less than the specified value? Go to Step 6. Go to Step 22.
Check for installation condition of the injector har-
ness connector, ECM connector and coupling con-
nector.
4 1. Check for play or looseness in the connection. —
2. If the trouble is detected, repair as required.
Is the resistance more than the specified value? Go to Step 8. Go to Step 10.
1. Turn the key switch to “OFF”.
2. Remove the ECM-side harness connector
from the coupling connector (H-95).
8 3. Measure the resistance between the No. 6 cyl- 10 MΩ
inder injector drive circuit (H95 male-side
No.6) and the ground.
Is the resistance more than the specified value? Go to Step 12. Go to Step 11.
1. Check the No. 4 cylinder injector drive circuit
between ECM and coupling connector (H-95)
for ground short circuit using breaker box or
DMM.
Refer to 1E-563, “Breaker box inspection pro-
cedure, DTC: P1262 (Flash code 159) Injec-
tion nozzle common 2 drive system fault, List
of Diagnostic Trouble Codes”.
9 Note: —
If breaker box is not available, refer to 1E-564,
“On-board check procedure for sensors, DTC:
P1262 (Flash code 159) Injection nozzle common 2
drive system fault, List of Diagnostic Trouble
Codes”.
2. If the trouble is detected, repair as required.
Is the resistance more than the specified value? Go to Step 14. Go to Step 23.
1. Turn the key switch to “OFF”.
2. Remove the injector-side harness connector
from the coupling connector (H-95).
3. Connect the DMM between the No. 4 cylinder
14 injector drive circuit (H95 female-side No. 2) 0V
and the ground.
4. Turn the key switch to “ON”.
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 3. Check the harness from coupling connector for
open circuit.
3 • If both steps 1 and 2 are faulty, repair the har-
ness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
A A Engine control
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
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
TSWG0081
Description of circuit The ECM sets the DTC when the difference in the
The accelerator position (AP) sensor is installed to the accelerator opening angle is large between which is
accelerator pedal. The AP sensor is the potentiometer- detected based on the AP sensor 1 signal, and which is
type sensor, and the value of output voltage changes detected based on the AP sensor 2 signal.
according to the accelerator opening angle. Two AP
sensors are installed, each of which includes following Main trouble symptom
circuits. 1 system fault: No backup
• 5-V power supply circuit 2 systems fault: Accelerator opening angle is controlled
to 0%.
• Ground circuit
• AP sensor signal circuit Preconditions when DTC is set
The ECM provides 5 V to the AP sensor through 5-V
power supply circuit, and grounds to the inside of the • Key switch input voltage is 16V or more.
ECM through ground circuit. Also, the AP sensor out- • DTC P1630, P1631, P1271, P1277, P1278,
puts the signal voltage to the ECM through AP sensor P1282, or P1283 is not detected.
signal circuit. When the accelerator opening angle is
large, the AP sensor 1 outputs high voltage, whereas DTC set condition
the AP sensor 2 outputs low voltage. Difference in opening angle between accelerator sen-
sors 1 and 2 is 45% or more.
1E-566 Electronic Control Fuel Injection System (Common Rail Type)
• [Accelerator sensor 1 voltage + Accelerator sensor • Using the scan tool, or memory clear switch and
2 voltage] is higher than 6.4 V. diagnostic switch operation enables to clear DTCs.
• [Accelerator sensor 1 voltage + Accelerator sensor
2 voltage] is lower than 3.6 V. Diagnostic aid
If the intermittent trouble is suspected, followings may
Action taken when DTC is set be the cause.
• Trouble is displayed on the monitor of the • Improper connection of harness connector
machine or diagnosis lamp comes on. • Defective harness routing
• Worn harness cladding
• Wire disconnection inside harness cladding
Back-up mode Following inspections are necessary to detect these
causes.
• 1 system fault...No back-up
• Improper connection of harness connector and
• 2 systems fault...Accelerator opening angle is con- ECM connector
trolled to 0%.
– Poor connection of terminal from connector
Recovery from failure – Unmatched terminals are fitted.
– Damage of connector lock
Refer to 1E-270, “List of Diagnostic Trouble Codes”
and “About recovery from failure” in this section for – Poor contact between terminal and wire
recovery from failure. • Damaged harness
– Visually check the harness for damage.
The conditions to clear the MIL/DTC
– Check the relevant items on the scan tool data
• The present trouble turns to history trouble when display while moving the connector and the har-
the condition is out of the range from DTC set con- ness which are related to the sensor. The varia-
dition (recovery from failure). tion of the display indicates the faulty part.
• The diagnosis lamp will go off after the code turns
to history trouble and the key switch is turned Test description
“OFF” then “ON” again. Numbers below indicate step numbers in the chart.
3. Measure at the harness connector-side.
6 Note: —
If breaker box is not available, refer to 1E-570,
“On-board check procedure for sensors, DTC:
P1271 (Flash code 24) Accelerator sensor 1-2
comparison fault, List of Diagnostic Trouble
Codes”.
2. If the trouble is detected, repair as required.
7 Note: —
If breaker box is not available, refer to 1E-570,
“On-board check procedure for sensors, DTC:
P1271 (Flash code 24) Accelerator sensor 1-2
comparison fault, List of Diagnostic Trouble
Codes”.
2. If the trouble is detected, repair as required.
8 Note: —
If breaker box is not available, refer to 1E-570,
“On-board check procedure for sensors, DTC:
P1271 (Flash code 24) Accelerator sensor 1-2
comparison fault, List of Diagnostic Trouble
Codes”.
2. If the trouble is detected, repair as required.
9 Note: —
If breaker box is not available, refer to 1E-570,
“On-board check procedure for sensors, DTC:
P1271 (Flash code 24) Accelerator sensor 1-2
comparison fault, List of Diagnostic Trouble
Codes”.
2. If the trouble is detected, repair as required.
About AP sensor
Refer to the machine’s manual for installing position of
the AP sensor.
Characteristics of AP sensor
(V)
Name
1
1. Breaker box
2. DMM
0 99.8 (%)
TSWG0200
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
A A Engine control
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
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
TSWG0081
(V)
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
A A Engine control
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
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
TSWG0081
(V)
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM
TSWG0197
1E-582 Electronic Control Fuel Injection System (Common Rail Type)
DTC: P1282 (Flash code 24) Accelerator sensor 2 fault (low voltage fault)
A A Engine control
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
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
TSWG0081
(V)
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
A A Engine control
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
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
TSWG0081
(V)
0 99.8 (%)
TSWG0200
Name
1. Breaker box
2. DMM
TSWG0197
Electronic Control Fuel Injection System (Common Rail Type) 1E-593
DTC: P1291 (Flash code 248) PCV circuit fault (PCV2 open circuit or GND short circuit)
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)
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
Engine
control
module
(ECM)
TSWG0077
Is the “PCV F/B” less than the specified value? Go to Step 4. Go to Step 5.
1. Check for followings in the circuit between
PCV and ECM using breaker box or DMM.
Refer to 1E-597, “Breaker box inspection pro-
cedure, DTC: P1291 (Flash code 248) PCV
circuit fault (PCV2 open circuit or GND short
circuit), List of Diagnostic Trouble Codes”.
Note:
If breaker box is not available, refer to 1E-598,
“On-board check procedure for sensors, DTC:
4 P1291 (Flash code 248) PCV circuit fault (PCV2 —
open circuit or GND short circuit), List of Diagnostic
Trouble Codes”.
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace as
required.
1 2
TSWG0010
Electronic Control Fuel Injection System (Common Rail Type) 1E-597
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. PCV-HI
2. PCV-LO
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
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
Engine
control
module
(ECM)
TSWG0077
TSWG0010
Name
1. PCV #1
2. PCV #2
Name
1. Breaker box
2. DMM
Name
1. PCV-HI
2. PCV-LO
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Engine
control
G sensor Common rail pressure module
signal sensor signal (ECM)
5V
CKP CKP
HIGH LOW
signal signal
98 E-56 101 E-56 100 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56
0.75
L
0.75 B
CKP sensor
1 E-112 2 E-112 3 E-112 1 E-113 2 E-113 3 E-113
TSWG0070
TSWG0064
Name
1. GND
2. Power supply
TSHK0128
1E-608 Electronic Control Fuel Injection System (Common Rail Type)
About G sensor About CKP sensor and G sensor signals
1 2 3 2
TSWG0065 TSWG0151
Name Name
1. Signal 1. CKP signal
2. GND 2. G sensor signal
3. Power supply
2
1
15
TSWG0199
Name
1. G sensor
2. Pulser
Electronic Control Fuel Injection System (Common Rail Type) 1E-609
DTC: P1625 (Flash code 416) Main relay fault
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)
(MAIN)* (30A)*
B+ B+
Engine control
module (ECM)
TSWG0071
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
A A Engine control
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
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
TSWG0081
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 1. Disconnect the coupling connector, and check the
sensor from engine harness connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
1E-622 Electronic Control Fuel Injection System (Common Rail Type)
DTC: P1632 (Flash code 55) Voltage fault in 5-V power supply 2
A A Engine control
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
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
TSWG0081
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 1. Disconnect the coupling connector, and check the
sensor from engine harness connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
1E-626 Electronic Control Fuel Injection System (Common Rail Type)
DTC: P1633 (Flash code 55) Voltage fault in 5-V power supply 3
(*: Specifications vary depending on each machine. Refer to the machine’s manual.)
Engine control
module (ECM)
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
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
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 1. Disconnect the coupling connector, and check the
sensor from engine harness connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
1E-630 Electronic Control Fuel Injection System (Common Rail Type)
DTC: P1634 (Flash code 55) Voltage fault in 5-V power supply 4
Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal
TSWG0079
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 1. Disconnect the coupling connector, and check the
sensor from engine harness connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
1E-634 Electronic Control Fuel Injection System (Common Rail Type)
DTC: P1635 (Flash code 55) Voltage fault in 5-V power supply 5
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
W U
EGR valve
TSWG0080
Name
1. Breaker box
2. DMM
On-board check procedure for sensors 1. Disconnect the coupling connector, and check the
sensor from engine harness connector.
3 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.
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
1E-638 Electronic Control Fuel Injection System (Common Rail Type)
DTC: U2104 (Flash code 84) CAN Bus fault
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
TSWG0074
Name
1. Breaker box
2. DMM
Short circuit to Resistance • Remove all the rel- 18 – Ground 10 MΩ or 100Ω or less
ground measurement evant ECU con- 37 – Ground more
nectors.
• Key switch “OFF”
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
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
TSWG0074
Name
1. Breaker box
2. DMM
2 1
TSWG0197
Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness
Symptom Description
Engine start failure Crank speed is slow.
Crank speed is normal but engine does not start (no first combustion).
Engine starts (first combustion exists) but cannot maintain stable
engine speed, or no blow up.
Engine stall Engine cranks but take long time before start. It operates eventually,
or starts but stops immediately.
Engine hunting, rough idling Engine idle speed is rough, or idle speed changes. In a more severe
case, engine or machine vibrates. In any serious situations, the
engine stalls.
Engine output shortage, lag down Engine output is lower than expected, and output does not change
with the accelerator lever (throttle lever) released, engine response
deteriorates.
Exhaust gas contains a lot of white smoke. A lot of white smoke emitted while running.
Exhaust gas contains a lot of black smoke. A lot of black smoke emitted while running.
Noise Abnormal sound occurs from the engine.
Fuel consumption deteriorates. Fuel consumption is remarkably more than that indicated in the
machine’s manual. The situation shown here is that the problem is
not found on the machine side and the engine needs to be checked.
Oil consumption deteriorates. Oil consumption is remarkably lower than that indicated in the
machine’s manual. The situation shown here is that the problem is
not found on the machine side and the engine needs to be checked.
Electronic Control Fuel Injection System (Common Rail Type) 1E-649
Engine start failure
Pre-inspection • Exhaust system parts for fault.
Before using this paragraph, perform the “OBD system
check” and check all the following items. Diagnostic aid
• Check if excessive load is applied to the machine • If the crank sensor is faulty, crank more than 60
side. rpm for 14 seconds or more since it is not judged
on cranking for less than 14 revolutions.
• ECM and diagnosis lamp operate properly.
• When the engine is running at low speed, the DTC
• Check the DTC.
of crank sensor fault may not be detected. If an
• Scan tool data shows normal operating range. intermittent trouble is found, raise the engine
• Check the condition of the machine to identify the speed up to No Load Max, and check if DTC
applicable symptom from “List of trouble symp- related to crank sensor is detected.
tom”. Perform the procedure described in the • Fuel system fault (run out of fuel, frozen fuel, air
symptom chart. mixed in fuel pipe, faulty filter [clog in main filter,
• Check with the customer if correct engine oil and gauze filter], pipe fault, fuel quality, fuel tank [for-
fuel are used. eign matter, fuel suction fault])
• Intake system fault (clogging in filter, intake pipe
Visual check fault, etc.)
Careful visual check is required for some symptom pro- • Supply pump fault (no fuel pressure feed)
cedures. By this inspection, the problem can be cor- • Common rail fault (flow damper or pressure limiter
rected without performing further inspection, and time is activated, degradation of sealability)
can be saved.
• Injector fault (no fuel injection)
This inspection includes the following items.
• There is no dirt or clogging in fuel filter. • System down due to trouble
• Engine body fault
• There is no poor contact in connector (it must be
(seizure, compression pressure shortage, other
connected with click sound). Especially for CKP
mechanical trouble)
sensor and G sensor.
• ACG trouble
• The terminal voltage of battery is not low.
• Machine side related equipment trouble
• Wire is connected, tightened or cut properly.
(oil pressure pump etc.)
• Commercial accessory power supply is not bifur-
• Effect of commercial electrical equipment (radio,
cated from ECM power supply.
lamp, etc.)
• ECM ground is not contaminated and installed to
the proper position securely. • ECM trouble
(body, power supply, ground, etc.)
• Pipes and hoses relevant to fuel, air and oil are
• Check the connector for poor contact, the harness
free of crack or twist, and are properly connected.
for fault such as wear or bend, and the wire inside
Thoroughly check for any oil leakage and clogging.
the harness for loosened wire causing short circuit
• Fuel system is free from oil leakage, and pipe is to other circuits. Also, perform the function diagno-
not damaged or dent. sis to check the operation and control of each part.
• Intake system parts for fault. Repair if faulty.
EGR valve check 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.
TSWG0150
1E-668 Electronic Control Fuel Injection System (Common Rail Type)
Noise
Pre-inspection • Pipes and hoses relevant to fuel, air and oil are
free of crack or twist, and are properly connected.
Before using this paragraph, perform the “OBD system
Thoroughly check for any oil leakage and clogging.
check” and check all the following items.
• Fuel system is free from oil leakage, and pipe is
• Check for noise by referring to the machine’s man-
not damaged or dent.
ual.
• ECM and diagnosis lamp operate properly. • Intake system parts for fault.
• Exhaust system parts for fault.
• Check the DTC.
• Scan tool data shows normal operating range. Diagnostic aid
• Check the condition of the machine to identify the
• Fuel system fault (run out of fuel, frozen fuel, air
applicable symptom from the table of contents.
mixed in fuel pipe, faulty filter [clog in main filter,
Perform the procedure described in the symptom
gauze filter], pipe fault, fuel quality, fuel tank [for-
chart.
eign matter, fuel suction fault])
• Check with the customer if correct engine oil and
• Intake system fault (EGR valve fault)
fuel are used.
• Injector fault (no fuel injection)
Visual check • Engine body fault (seizure, compression pressure
shortage, other mechanical trouble)
Careful visual check is required for some symptom pro-
cedures. By this inspection, the problem can be cor- • Machine side related equipment trouble (oil pres-
rected without performing further inspection, and time sure pump etc.)
can be saved. This inspection includes the following • ECM trouble (body, power supply, ground, etc.)
items. • Check the connector for poor contact, the harness
• Wire is connected, tightened or cut properly. for fault such as wear or bend, and the wire inside
• ECM ground is not contaminated and installed to the harness for loosened wire causing short circuit
the proper position securely. to other circuits. Also, perform the function diagno-
sis to check the operation and control of each part.
Repair if faulty.
3 1
6 7 8 9 10
TSWG0163
Name
1. Exhaust pipe 6. Secondary EGR cooler
2. To intercooler 7. From intercooler
3. From air cleaner 8. EGR valve
4. EGR duct 9. EGR duct
5. Primary EGR cooler 10. EGR duct
Check the above intake/exhaust system for fault such as clogging, crush or breakage.
Besides the inspection location of engine body, check the air cleaner, intercooler and muffler.
Electronic Control Fuel Injection System (Common Rail Type) 1E-673
Oil consumption deteriorates.
Pre-inspection Visual check
Before using this paragraph, perform the “OBD system Careful visual check is required for some symptom pro-
check” and check all the following items. cedures. By this inspection, the problem can be cor-
• Oil consumption varies depending on handling of rected without performing further inspection, and time
each machine. Check Hitachi Construction can be saved. This inspection includes the following
Machinery’s measure of oil consumption (A). items.
Measure of oil consumption/hour. Measure of oil • If bluish-white smoke is emitted continuously while
consumption for engine alone: 4 L {4.2 qts}/ 100 engine running.
hours • If blow-by gas is emitted.
• Check the actual oil consumption (B). Actual oil • If oil is mixed in the coolant.
consumption /hour
• Pipes and hoses relevant to oil are free of crack or
• Refer to the list of inspection and maintenance twist, and are properly connected. Thoroughly
items of the operation manual for proper inspection check for any oil leakage and clogging.
depending on the operation time.
• Lubrication system is free from oil leakage, and
• If the operation time exceeds 3000 hours, inspect pipe is not damaged or dent.
by referring to the machine’s manual.
• Intake system parts for fault (turbocharger check).
• ECM and diagnosis lamp operate properly.
• Check the DTC. Diagnostic aid
• Check the condition of the machine to identify the • Intake system fault (rise/decline of oil, excessive
applicable symptom from the table of contents. blow-by gas)
Perform the procedure described in the symptom • Engine body fault (oil combustion, excessive blow-
chart. by gas)
• Check with the customer if correct engine oil and Also, perform the function diagnosis to check the oper-
fuel are used. ation and control of each part. Repair if faulty.
Special Tool
List of Special Tool Illustration Tool No. / Tool name
Injector checker
5-8840-2691-0
Digital multimeter
IJC
Tech2
Scan tool
5-8840-0632-0
Terminal remover
5-8840-0388-0
Weather pack terminal
remover
5-8840-0385-0
Breaker box
5884003850
EMPS
1E-676 Electronic Control Fuel Injection System (Common Rail Type)
SPN FMI P Code DTC description Trouble SPN FMI P Code DTC description Trouble
display display
on on
monitor monitor
10005 1 P0611 Charge circuit fault 1079 2 P1631 Voltage fault in 5-V
❍ ❍
(bank 1) power supply 1
10006 1 P0612 Charge circuit fault 1080 2 P1632 Voltage fault in 5-V
❍ ❍
(bank 2) power supply 2
677 3 P0615 Starter cut relay fault ❍ 10009 2 P1633 Voltage fault in 5-V
❍
power supply 3
987 3 P0650 Check engine lamp
❍
fault 10010 2 P1634 Voltage fault in 5-V
❍
power supply 4
1240 1 P1093 No pump pressure
❍
feed (fuel leakage) 10011 2 P1635 Voltage fault in 5-V
❍
power supply 5
1239 1 P1094 No pump pressure
❍
feed (1st stage) 639 2 U2104 CAN Bus fault ❍
633 7 P1095 Pressure limiter open ❍ 639 3 U2106 CAN timeout fault ❍
105 4 P1112 Boost temperature
sensor fault (low volt- ❍ How to clear DTC
age fault) 1. Connect the harness for memory clear to the data
105 3 P1113 Boost temperature link connector.
sensor fault (high volt- ❍
age fault)
110 0 P1173 Overheat ❍
968 2 P1225 Idle up/down switch
❍
fault
10003 2 P1261 Injection nozzle com-
mon 1 drive system ❍
fault
10004 2 P1262 Injection nozzle com-
mon 2 drive system ❍
fault
91 2 P1271 Accelerator sensor 1-2
❍
comparison fault
91 3 P1277 Accelerator sensor 1
❍
fault (low voltage fault)
91 4 P1278 Accelerator sensor 1
TSWG0209
fault (high voltage ❍
fault) 2. Turn the key switch to ON.
91 3 P1282 Accelerator sensor 2
3. Connect the memory clear terminal to the ground
❍ for 1 second or more.
fault (low voltage fault)
4. Turn the key switch to OFF. (Memory will be
91 4 P1283 Accelerator sensor 2
fault (high voltage ❍
cleared when the key switch is OFF.)
fault) 5. Disconnect the diagnosis switch terminal.
1348 0 P1291 PCV2 open circuit or
❍
ground short
1348 4 P1292 PCV2 +B short ❍
636 7 P1345 Cam sensor out of
❍
phase
1485 2 P1625 Main relay system fault
❍
(Not enter)
10008 2 P1630 A/D conversion fault ❍
1E-678 Electronic Control Fuel Injection System (Common Rail Type)
About wiring diagrams
• There are some sensors which are not connected to the ECM depending on the machine.
• Check the specifications of the machine, since some sensors input/output to ECM via CAN communication.
(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)*
(10A)*
46 94 U
EGR valve
Key switch (ST) 93 V
Battery position sensor
Starter relay 92 W
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
TSWG0183
Electronic Control Fuel Injection System (Common Rail Type) 1E-679
List of DTC that vary depending on the machine manufacturer
On some machines, the diagnosis lamp comes on instead of trouble display monitor on the machine.
Recovery
Flash DTC Item to be Preconditions when Judgment Behavior when Diagno-
DTC DTC set condition from
code description detected DTC is set time trouble occurs sis lamp
failure
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
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,
P0202 272 Open circuit Open/short • Main relay power No injector 2 Approx. 3 Intensive engine ON *1
in injection circuit in elec- supply voltage is monitor input sig- sec. vibration, rough
nozzle #2 trical wiring 16V or more. nal exists. idling, output lower-
drive system No. 2 cylinder • 70 rpm or more ing, blow up fault
injector • DTC P0611, Back-up:
P1261 or P0202 is Injection for cylin-
not detected. der #3 stopped,
1E-680 Electronic Control Fuel Injection System (Common Rail Type)
Recovery
Flash DTC Item to be Preconditions when Judgment Behavior when Diagno-
DTC DTC set condition from
code description detected DTC is set time trouble occurs sis lamp
failure
P0203 273 Open circuit Open/short • Main relay power No injector 3 Approx. 3 Intensive engine ON *1
in injection circuit in elec- supply voltage is monitor input sig- sec. vibration, rough
nozzle #3 trical wiring 16V or more. nal exists. idling, output lower-
drive system No. 3 cylinder • 70 rpm or more ing, blow up fault
injector • DTC P0611, Back-up:
P1261 or P0203 is Injection for cylin-
not detected. der #6 stopped,
P0204 274 Open circuit Open/short • Main relay power No injector 4 Approx. 3 Intensive engine ON *1
in injection circuit in elec- supply voltage is monitor input sig- sec. vibration, rough
nozzle #4 trical wiring 16V or more. nal exists. idling, output lower-
drive system No. 4 cylinder • 70 rpm or more ing, blow up fault
injector • DTC P0612, Back-up:
P1262 or P0204 is Injection for cylin-
not detected. der #2 stopped,
P0205 275 Open circuit Open/short • Main relay power No injector 5 Approx. 3 Intensive engine ON *1
in injection circuit in elec- supply voltage is monitor input sig- sec. vibration, rough
nozzle #5 trical wiring 16V or more. nal exists. idling, output lower-
drive system No. 5 cylinder • 70 rpm or more ing, blow up fault
injector • DTC P0612, Back-up:
P1262 or P0205 is Injection for cylin-
not detected. der #4 stopped,
P0206 276 Open circuit Open/short • Main relay power No injector 6 Approx. 3 Intensive engine ON *1
in injection circuit in elec- supply voltage is monitor input sig- sec. vibration, rough
nozzle #6 trical wiring 16V or more. nal exists. idling, output lower-
drive system No. 6 cylinder • 70 rpm or more ing, blow up fault
injector • DTC P0612, Back-up:
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
P0606 51 CPU fault CPU fault Sub-CPU detects Nearly Output lowering ON *2
main CPU fault in simulta- Back-up:
100 msec after neous to Limited injection
— key switch ON. fault amount 2 (multi-
(SUB-CPU resets occur- injection stopped)
CPU.) rence SUB-CPU stops
CPU.
52 CPU monitor- Sub-CPU • 480 msec or more RUN-SUB pulse Nearly Output lowering ON *2
ing IC fault fault has elapsed after does not change simulta- Back-up:
key switch ON. for 20 msec or neous to Limited injection
• Key switch input more. fault amount 1
power supply volt- occur-
age is higher than rence
16 V.
Electronic Control Fuel Injection System (Common Rail Type) 1E-681
Recovery
Flash DTC Item to be Preconditions when Judgment Behavior when Diagno-
DTC DTC set condition from
code description detected DTC is set time trouble occurs sis lamp
failure
P0611 34 Charge cir- ECM charge • Main relay power When charge cir- Approx. Intensive engine ON *2
cuit fault circuit 1 fault supply voltage is cuit bank 1 volt- 1.5 sec. vibration, rough
(bank 1) (internal 16V or more. age inside ECM is idling, output lower-
burnout, low. ing, blow up fault,
open circuit, engine stall are pos-
etc.) sible.
Back-up:
Common 1 stop
(#1, #2, #3 cylin-
ders stopped)
P0612 Charge cir- ECM charge When charge cir- Approx. Intensive engine ON *2
cuit fault circuit 2 fault cuit bank 2 volt- 1.5 sec. vibration, rough
(bank 2) (internal age inside ECM is idling, output lower-
burnout, low. ing, blow up fault,
open circuit, engine stall are pos-
etc.) sible.
Back-up:
Common 2 stop
(#4, #5, #6 cylin-
ders stopped)
P1113 295 Boost tem- Short circuit • Key switch input Boost tempera- Approx. 4 Operationality is not ON *2
perature sen- in sensor or voltage is 16V or ture sensor volt- sec. affected.
sor fault (high harness more. age is more than Back-up:
voltage fault) • Coolant tempera- 4.94V. No back-up action
ture is 50°C (122°F)
or more.
• 3 (or 5) minutes
have passed after
engine starting
• DTC P1634 is not
detected.
P1261 158 Injection noz- Open/short • Main relay power No injector 1, 2, 3 Approx. 3 Intensive engine ON *1
zle common circuit in supply voltage is monitor input sig- sec. vibration, rough
1 drive sys- injector com- 16V or more. nal exists. idling, output lower-
tem fault mon 1-side • 70 rpm or more ing, blow up fault
electrical wir- • None of the follow- Engine stall is possi-
ing, EDU out- ing DTC sets are ble.
put part fault detected; DTC Back-up:
P0611, P1261 and Common 1 stop
P0201; DTC P0611, (#1, #2, #3 cylin-
P1261 and P0202; ders stopped)
DTC P0611, P1261
and P0203.
P1262 159 Injection noz- Open/short • Main relay power No injector 4, 5, 6 Approx. 3 Intensive engine ON *1
zle common circuit in supply voltage is monitor input sig- sec. vibration, rough
2 drive sys- injector com- 16V or more. nal exists. idling, output lower-
tem fault mon 2-side • 70 rpm or more ing, blow up fault
electrical wir- • None of the follow- Engine stall is possi-
ing, EDU out- ing DTC sets are ble.
put part fault detected; DTC Back-up:
P0612, P1262 and Common 2 stop
P0204; DTC P0612, (#1, #2, #3 cylin-
P1262 and P0205; ders stopped)
DTC P0612, P1262
and P0206.
P1634 55 Voltage fault Power sup- • DTC P1630 is not 5-V 4 power sup- Approx. Operationality is ON *2
in 5-V power ply wiring detected. ply voltage is 5.5 0.5 sec. affected.
supply 4 short to sen- • Key switch input V or more, or 4.5 Back-up:
sor, or break- power supply volt- V or less. Same to boost
age in age is between 16 pressure sensor
element/cir- and 32 V. fault
cuit for power
supply regu-
lation inside
ECM.
1E-682 Electronic Control Fuel Injection System (Common Rail Type)
Recovery
Flash DTC Item to be Preconditions when Judgment Behavior when Diagno-
DTC DTC set condition from
code description detected DTC is set time trouble occurs sis lamp
failure
U2104 84 CAN Bus CAN commu- • Key switch input Bus-off is At 3 sec. Vary depending on ON *3
fault nication fault voltage is 12 V or detected. continu- setting.
more. ously Back-up:
Switched to drive
control by acceler-
ator sensor input
voltage
U2106 85 CAN timeout CAN commu- • DTC U2104 is not CAN data recep- At 1 sec. Vary depending on ON *3
fault nication fault detected. tion does not continu- setting.
• Key switch input complete at a set ously Back-up:
voltage is 12 V or time. Switched to drive
more. control by acceler-
ator sensor input
voltage
*1, *2, *3: Refer to 1E-270, “List of Diagnostic Trouble Codes” in this section.