Introduction

This Troubleshooting Manual describes the structure and the troubleshooting of

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

Isuzu Motors Limited

Off-highway Powertrain
Operation Dept.
 Control System
Engine Control
(Electronic control fuel injection system (Common rail type))
Table of Contents
How to use this manual . . . . . . . . . . . . . . . . . . . . 1E-3 Scan tool communication circuit system check
Table of abbreviation . . . . . . . . . . . . . . . . . . . . . 1E-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-209
List of parts according to engine control specifications Starting circuit system check . . . . . . . . . . . . . 1E-212
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-5 Starting system check . . . . . . . . . . . . . . . . . . 1E-218
About colors of wirings . . . . . . . . . . . . . . . . . . . 1E-6 Fuel system check. . . . . . . . . . . . . . . . . . . . . 1E-221
About wiring diagrams. . . . . . . . . . . . . . . . . . . . 1E-7 Intake system check . . . . . . . . . . . . . . . . . . . 1E-223
Precautions on Service Work . . . . . . . . . . . . . . . 1E-10 Exhaust system check. . . . . . . . . . . . . . . . . . 1E-224
Procedure of trouble diagnosis . . . . . . . . . . . . . 1E-11 EGR control system check . . . . . . . . . . . . . . 1E-225
Interview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-13 QOS system check . . . . . . . . . . . . . . . . . . . . 1E-228
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1E-15 List of diagnostic trouble code . . . . . . . . . . . . . 1E-233
Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . . 1E-15 DTC: P0087 (Flash code 227) Common rail low
How to read DTC . . . . . . . . . . . . . . . . . . . . . . 1E-16 pressure fault (No pressure feed in supply pump)
Confirmation after repair . . . . . . . . . . . . . . . . . 1E-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-257
List of final check items . . . . . . . . . . . . . . . . . . 1E-18 DTC: P0088 (Flash code 118) Common rail pressure
How to clear DTC . . . . . . . . . . . . . . . . . . . . . . 1E-19 is abnormally high (1st or 2nd stage) . . . . . . 1E-265
Trouble diagnosis with scan tool . . . . . . . . . . . 1E-20 DTC: P0089 (Flash code 151) Common rail pressure
How to use trouble diagnosis-related tool . . . . . 1E-25 fault (Excessive pressure feed in supply pump)
How to use Tech2 . . . . . . . . . . . . . . . . . . . . . . 1E-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-270
Injector balance test . . . . . . . . . . . . . . . . . . . . 1E-43 DTC: P0090 (Flash code 247) SCV drive system
Rewrite setting of Q adjust data by Tech2. . . . 1E-48 open circuit, +B short or ground short . . . . . . 1E-275
How to use TIS 2000. . . . . . . . . . . . . . . . . . . . 1E-68 DTC: P0107 (Flash code 71) Barometric pressure
How to Inspect Injector. . . . . . . . . . . . . . . . . . . . 1E-78 sensor circuit input is low (open circuit or ground
How to use injector checker . . . . . . . . . . . . . . 1E-78 short). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-281
Method to identify using non-contact infrared DTC: P0108 (Flash code 71) Barometric pressure
thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-82 sensor circuit input is high (+5 V short) . . . . . 1E-288
How to use flash tool . . . . . . . . . . . . . . . . . . . . . 1E-84 DTC: P0112 (Flash code 22) Intake air temperature
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-84 sensor fault (low voltage fault, GND short, short
Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-85 circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-295
EMPS Component Parts . . . . . . . . . . . . . . . . . 1E-87 DTC: P0113 (Flash code 22) Intake air temperature
ECM (Hardware) Compatibility . . . . . . . . . . . . 1E-88 sensor fault (high voltage fault, open circuit or short to
System Requirements for EMPS Software power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-301
(Recommended) . . . . . . . . . . . . . . . . . . . . . . . 1E-88 DTC: P0117 (Flash code 23) Engine coolant
EMPS (Software) Setup Procedure . . . . . . . . 1E-89 temperature sensor fault (low voltage fault, GND
EMPS Operation Procedure . . . . . . . . . . . . . . 1E-93 short, short circuit) . . . . . . . . . . . . . . . . . . . . . 1E-309
How to use breaker box . . . . . . . . . . . . . . . . . . 1E-135 DTC: P0118 (Flash code 23) Engine coolant
Engine Control System . . . . . . . . . . . . . . . . . . 1E-138 temperature sensor input is high (open circuit or short
Description of function and operation . . . . . . 1E-138 to power supply) . . . . . . . . . . . . . . . . . . . . . . 1E-316
Engine Control Module (ECM) . . . . . . . . . . . 1E-147 DTC: P0182 (Flash code 211) Fuel temperature
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . 1E-168 sensor fault (low voltage fault, GND short) . . 1E-324
Engine harness location . . . . . . . . . . . . . . . . 1E-184 DTC: P0183 (Flash code 211) Fuel temperature
Connector list . . . . . . . . . . . . . . . . . . . . . . . . 1E-196 sensor fault (high voltage fault, open circuit or short to
List of function checks . . . . . . . . . . . . . . . . . . . 1E-199 power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-330
OBD system check . . . . . . . . . . . . . . . . . . . . 1E-200 DTC: P0192 (Flash code 245) Common rail pressure
Diagnosis lamp illumination circuit system check sensor fault (low voltage fault, short circuit) . 1E-338
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-202 DTC: P0193 (Flash code 245) Common rail pressure
Diagnosis lamp blinking circuit system check sensor fault (high voltage fault) . . . . . . . . . . . 1E-344
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-204 DTC: P0201 (Flash code 271) Open circuit in
Scan tool power supply circuit system check 1E-207 injection nozzle #1 drive system . . . . . . . . . . 1E-351
1E-2 Electronic control fuel injection system (Common rail type)
DTC: P0202 (Flash code 272) Open circuit in DTC: P1225 (Flash code 31) Idle UP/DOWN switch
injection nozzle #2 drive system . . . . . . . . . . 1E-358 fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-522
DTC: P0203 (Flash code 273) Open circuit in DTC: P1261 (Flash code 158) Injection nozzle
injection nozzle #3 drive system . . . . . . . . . . 1E-365 common 1 drive system fault. . . . . . . . . . . . . 1E-526
DTC: P0204 (Flash code 274) Open circuit in DTC: P1262 (Flash code 159) Injection nozzle
injection nozzle #4 drive system . . . . . . . . . . 1E-372 common 2 drive system fault. . . . . . . . . . . . . 1E-537
DTC: P0205 (Flash code 275) Open circuit in DTC: P1271 (Flash code 24) Accelerator sensor 1-2
injection nozzle #5 drive system . . . . . . . . . . 1E-379 comparison fault . . . . . . . . . . . . . . . . . . . . . . 1E-548
DTC: P0206 (Flash code 276) Open circuit in DTC: P1277 (Flash code 24) Accelerator sensor 1
injection nozzle #6 drive system . . . . . . . . . . 1E-384 fault (low voltage fault). . . . . . . . . . . . . . . . . . 1E-554
DTC: P0219 (Flash code 543) Overrun . . . . 1E-389 DTC: P1278 (Flash code 24) Accelerator sensor 1
DTC: P0237 (Flash code 32) Boost sensor pressure fault (high voltage fault) . . . . . . . . . . . . . . . . . 1E-559
fault (low voltage fault, open circuit) . . . . . . . 1E-391 DTC: P1282 (Flash code 24) Accelerator sensor 2
DTC: P0238 (Flash code 32) Boost pressure sensor fault (low voltage fault). . . . . . . . . . . . . . . . . . 1E-564
fault (high voltage fault, short to power supply circuit, DTC: P1283 (Flash code 24) Accelerator sensor 2
ground open circuit) . . . . . . . . . . . . . . . . . . . 1E-398 fault (high voltage fault) . . . . . . . . . . . . . . . . . 1E-569
DTC: P0335 (Flash code 15) Crank sensor fault (no DTC: P1345 (Flash code 16) Cam sensor out of
signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-405 phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-574
DTC: P0336 (Flash code 15) Crank sensor fault DTC: P1625 (Flash code 416) Main relay fault
(signal fault). . . . . . . . . . . . . . . . . . . . . . . . . . 1E-412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-579
DTC: P0340 (Flash code 14) Cam sensor fault (no DTC: P1630 (Flash code 36) A/D conversion fault
signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-418 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-586
DTC: P0341 (Flash code 14) Cam sensor fault (signal DTC: P1631 (Flash code 55) Voltage fault in 5-V
fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-425 power supply 1 . . . . . . . . . . . . . . . . . . . . . . . 1E-588
DTC: P0380 (Flash code 66) Glow relay circuit fault DTC: P1632 (Flash code 55) Voltage fault in 5-V
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-431 power supply 2 . . . . . . . . . . . . . . . . . . . . . . . 1E-591
DTC: P0381 (Flash code 67) Glow plug lamp circuit DTC: P1633 (Flash code 55) Voltage fault in 5-V
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-436 power supply 3 . . . . . . . . . . . . . . . . . . . . . . . 1E-594
DTC: P0487 (Flash code 44) EGR position sensor DTC: P1634 (Flash code 55) Voltage fault in 5-V
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-441 power supply 4 . . . . . . . . . . . . . . . . . . . . . . . 1E-597
DTC: P0488 (Flash code 45) EGR valve control fault DTC: P1635 (Flash code 55) Voltage fault in 5-V
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-447 power supply 5 . . . . . . . . . . . . . . . . . . . . . . . 1E-600
DTC: P0522 (Flash code 294) Engine oil pressure DTC: U2104 (Flash code 84) CAN Bus fault
sensor fault (low voltage fault, open circuit, ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-603
short) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-453 DTC: U2106 (Flash code 85) CAN timeout fault
DTC: P0523 (Flash code 295) Engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-608
sensor fault (high voltage fault, short to power supply, List of trouble symptom . . . . . . . . . . . . . . . . . . 1E-613
ground short). . . . . . . . . . . . . . . . . . . . . . . . . 1E-459 Engine start failure. . . . . . . . . . . . . . . . . . . . . 1E-614
DTC: P0601 (Flash code 53) ROM fault . . . . 1E-467 Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-618
DTC: P0603 (Flash code 54) EEPROM fault Engine hunting, rough idling . . . . . . . . . . . . . 1E-622
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-469 Engine output shortage . . . . . . . . . . . . . . . . . 1E-626
DTC: P0606 (Flash code 51/52) CPU fault Exhaust gas contains a lot of white smoke.. . 1E-631
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-471 Exhaust gas contains a lot of black smoke.. . 1E-634
DTC: P0611 (Flash code 34) Charge circuit fault Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-637
(bank 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-473 Fuel consumption deteriorates. . . . . . . . . . . . 1E-639
DTC: P0612 (Flash code 34) Charge circuit fault Oil consumption deteriorates. . . . . . . . . . . . . 1E-642
(bank 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-476 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-644
DTC: P0650 (Flash code 77) Diagnosis lamp circuit Difference by each machine manufacturer. . . . 1E-645
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-479 Sumitomo (S.H.I.) Construction Machinery
DTC: P1093 (Flash code 227) No pump pressure Manufacturing Co., Ltd. . . . . . . . . . . . . . . . . . 1E-645
feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-484 About wiring diagrams . . . . . . . . . . . . . . . . . . 1E-652
DTC: P1095 (Flash code 225) Pressure limiter open Tech2 reference value . . . . . . . . . . . . . . . . . . 1E-654
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-493 Method to identify faulty injector . . . . . . . . . . 1E-657
DTC: P1112 (Flash code 295) Boost temperature
sensor fault (low voltage fault, ground short)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-502
DTC: P1113 (Flash code 295) Boost temperature
sensor fault (high voltage fault, open circuit, short to
power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-510
DTC: P1173 (Flash code 542) Overheat. . . . 1E-516
 Electronic control fuel injection system (Common rail type) 1E-3

How to use this manual

This manual describes about engine-related trouble diagnosis, and is closely related
to the machine trouble diagnosis. Always refer to both manuals for the trouble
diagnosis.

This manual consists of the following contents. This section “How to use this manual”
describes about abbreviations and instructions to use this manual. Therefore, if you
are familiar with Isuzu manuals, start with Precautions on service work and Basic
procedure of trouble diagnosis.

How to use this manual

• Table of abbreviation
• List of parts according to engine control specifications
• Wiring color code
• How to use wiring diagram

Precautions on service work

Procedure of trouble diagnosis

How to use trouble diagnosis-related tool

• How to use scan tool
• How to use TIS 2000
• How to use injector checker
• How to use flash tool
• How to use breaker box

Engine control system

List of function checks

List of diagnostic trouble codes

List of trouble symptom

1E-4 Electronic control fuel injection system (Common rail type)
Table of abbreviation

Abbreviation Name Meaning and remarks

A/D Analog/Digital Analog/Digital
AP Accelerator Position Accelerator opening angle
CAN Controller Area Network Communication system used to communicate between
ECM and the machine control unit
CKP Crankshaft Position Crankshaft (the sensor is installed onto flywheel
housing) position
C/U Control/Unit Abbreviation of control unit
CMP Camshaft Position Camshaft (the sensor is installed onto the rear of
cylinder head) position
DLC Data Link Connector Connector for scan tool (also known as: Checker
connector)
EMPS Engine Module Programming System Rewriting of control program in ECM
DMM Digital Multi-Meter Diagnostic tester for electrical equipment system (5-
8840-2691-0)
DTC Diagnostic Trouble Code Self-diagnosis code numbers which indicate trouble
condition
ECT Engine Coolant Temperature Engine coolant temperature
ECM Engine Control Module Core of engine control in engine control computer
ECU Electronic Control Unit Computer for various control
EGR Exhaust Gas Recirculation Recirculation system which mixes exhaust gas from
engine with intake air again to lower the combustion
temperature resulting in reduction of NOx.
EMI Electro Magnetic Interference Electro Magnetic Interference
Exh Exhaust Exhaust
F/B Feed/Back Abbreviation of feedback
FT Fuel Temperature Fuel temperature (the sensor is installed onto supply
pump.)
GND Ground Ground/Earth
IAT Intake Air Temperature Intake air temperature
J/C Joint/Connection Connector which connects each harness
MIL Malfunction Indicator Lamp Warning lamp MIL (diagnosis lamp)
PC Pressure Control Pressure control/Common rail pressure
SCV Suction Control Valve Valve which controls fuel flow to common rail and is
installed onto supply pump
PCV Pressure Control Valve Valve which controls fuel flow to common rail and is
installed onto supply pump
PWM Pulse Width Modulation Pulse width modulated wave
QOS Quick On Start Warming-up device
RP Rail Pressure Pressure in common rail
SBF Slow Blow Fuse Slow-blow type fuse which protects circuits of battery,
motor, etc.
 Electronic control fuel injection system (Common rail type) 1E-5

Abbreviation Name Meaning and remarks

SIG Signal Signal
VSS Vehicle Speed Sensor Sensor used to detect vehicle speed to control meters
or engine
W/S Weld/Splice Joint of each harness without connector

List of parts according to engine control specifications

Engine
Function
6W 6U 6H 4H 4J
PCV ❍ ❍ Controls the fuel pressure feed of supply pump.
SCV ❍ ❍ ❍ Controls the fuel pressure feed of supply pump.
CMP sensor ❍ ❍ ❍ Detects camshaft position of engine (used for identifying cylinder.)
G sensor Detects cam position of supply pump (used for identifying
❍ ❍
cylinder.)
CKP sensor ❍ ❍ ❍ ❍ ❍ Detects crankshaft position (used for engine control in general.)
1E-6 Electronic control fuel injection system (Common rail type)
About colors of wirings
All harnesses are identified by using different colors of
claddings. The harness for the main circuit in a certain
electrical system is identified by using a single color,
while the harness for the sub circuit uses a color in
stripes. Sizes and colors coding in a wiring diagram are
as follows.

e.g.
Red (stripe color)

Green (base color)

Harness size(0.5mm2)

Name
1. Single color
2. Color stripe

Symbol Color Symbol Color

B Black BR Brown
W White LG Light green
R Red GR Grey
G Green P Pink
Y Yellow SB Sky blue
L Blue V Violet
O Orange
 Electronic control fuel injection system (Common rail type) 1E-7
About wiring diagrams

Engine control
module (ECM)

Vehicle speed Engine oil pressure

sensor signal SV SV sensor signal
SV

CKP CKP Engine coolant

Fuel temperature Vcc
HIGH LOW temperature
signal signal sensor signal
sensor signal

108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56

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

4

0.75 0.75 0.75

3 H-20 2 H-20 1 H-20 B/Y L/Y W/B
0.75 0.75 0.75 0.75
Y/G B/Y R/B B/Y

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

Pulse
0.5 0.5 matching
V/W Y box

Engine
2 E-98 1 E-98 coolant
Fuel temperature sensor temperature Engine oil pressure sensor
sensor

3 E-90

CKP sensor A
*
CAN LOW CAN HIGH Engine
0.75 control
R module
(ECM)
Vehicle
speed sensor 37 E-57 18 E-57

4 H-6
A

Meter
Machine
control unit
CAN HIGH CAN LOW

Engine
coolant
temperature Machine trouble
gauge diagnosis monitor

TSWG0078

TSWG0120

1. Sections surrounded by long broken lines are used

to indicate the units, such as ECM.
2. Sections surrounded by dotted lines are used to
classify or differentiate the specifications of
machines. Confirmation of specifications is
needed.
3. Sections surrounded by dotted lines and marked
with a symbol (“A” in example) on the upper left are
used to classify different wiring in the 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)

Precautions on Service Work

Use of tools for circuit test Caution:
If there are no special instructions according to the The following guidelines should be followed to
diagnostic procedure, test lights must not be used in prevent the damage caused by electrostatic
the diagnosis of electric system of powertrain. Use a discharge:
connector test adaptor kit 5-8840-0385-0 when a probe • Do not touch the ECM connector pins or the
connector is required during the diagnostic procedure. electronic components soldered on to the
circuit board of the ECM.
Commercial electrical equipment • Package of that part should not be opened until
Commercial electrical equipment means that the preparation of the installation of the
commercial electrical components installed to a replacement part is completed.
machine after shipment from factory. Be careful that no • Connect that package to the normal grounding
special consideration for this equipment is taken in the on the machine before taking out the parts from
design process of the machine. the package.
• If handling the parts with moving seats in
Caution: sliding, or sitting down from the standing
Connect commercial electrical equipment to the position, or walking for a certain distance, it is
circuit whose power supply and ground wires are required to touch the normal grounding before
not related to the electronic control system. the installation of the parts.

Commercial electrical equipment may cause Fuel pipe

malfunction of the electronic control system even if they
are installed properly. They include devices which are
not connected to the electrical systems on the machine,
such as mobile phones or radios. Therefore, in trouble
1
diagnosis of powertrain, first check if this commercial
electrical equipment is installed, and if so, remove it 2
from the machine. If the trouble has not been solved
after the removal, diagnose it in usual procedures.

Welding work on the machine

If performing welding on the machine, remove the
battery in advance. Otherwise, the current during
welding may cause system trouble or damage.

Damage caused by electrostatic discharge 3

The electronic components used in the electronic 5
4
control systems are easy to get damaged, caused by
electrostatic discharge because they are designed to
operate in a very low voltage. Some kinds of electronic TSHK0134

components may get damaged by electrostatic in even Name

less than 100 V which human cannot feel. For 1. Injector pipe
reference sake, the voltage of 4,000 V is needed for 2. Flow damper
human to feel the flow of electrostatic discharge. 3. Common rail
There are several ways for human body to have 4. Common rail pressure sensor
electrostatic charged. The common way to be charged 5. Pressure limiter
is caused by friction or induction.
• For example, a charging by friction is caused when • Do not reuse the high-pressure pipe and injector
a person slides on the seat of the machine. pipe of the fuel system. Replace with new one if it
• A charging by induction occurs when a person who is removed.
wears well-insulated shoes stands near the high- • Never replace the pressure limiter, fuel
electrified object and then he grounds instantly. temperature sensor, flow damper alone. If faulty,
The same electric charge flows out and that person replace the common rail assembly and all the fuel
is charged in the high opposite electric charge. It is pipes.
important to be careful in handling or testing the
electronic components because electrostatic
causes damage.
 Electronic control fuel injection system (Common rail type) 1E-11

Procedure of trouble diagnosis

The following diagnostic procedure is extremely important to solve the problems of all electric/electronic (E/E)
systems. Failure to perform this procedure may require unnecessary repair. Read carefully this procedure to
understand, and then perform trouble diagnosis.
In addition, use the effective function or a scan tool to perform trouble diagnosis and system check.

ECM control
DTC

Sensor output

Data Link Connector

Read DTC Actuator Test

V
V
RPM
RPM
Snapshot V
V
%

TSWG0121
1E-12 Electronic control fuel injection system (Common rail type)
Step 1 Confirm the user’s complaint
• Organize the trouble conditions using a check list.

Step 2 Perform pre-inspection

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

Step 3 Check service information

• Check service bulletins for the market.

Step 4 Check according to each DTC

• Check the items indicated by the diagnostic trouble code (DTC)

Step 5 Perform fault inspection for each symptom

• Check the items not indicated by the diagnostic trouble code (DTC)

Information:
Control System
Engine Control
(Electronic control fuel injection system (Common rail type)) About types of system trouble diagnosis
Table of Contents
Engine Control System . . . . . . . . . . . . . . . . . . . 10D-4
Precautions on service work . . . . . . . . . . . . . . 10D-4
Description of function and operation . . . . . . . 10D-7
DTC: P0238 (Flush code 32). . . . . . . . . . . . 10D-230
DTC: P0335 (Flush code 15). . . . . . . . . . . . 10D-235
DTC: P0336 (Flush code 15). . . . . . . . . . . . 10D-240
System diagnostic method is a standardized method to
1 Engine component location diagram. . . . . . . 10D-16
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . 10D-28
Procedure of trouble diagnosis . . . . . . . . . . . 10D-47
DTC: P0107 (Flush code 71) . . . . . . . . . . . 10D-143
DTC: P0340 (Flush code 14). . . . . . . . . . . . 10D-244
DTC: P0341 (Flush code 14). . . . . . . . . . . . 10D-249
DTC: P0487 (Flush code 44). . . . . . . . . . . . 10D-262
repair all the electric/electronic (E/E) systems. The
faults in E/E system often occur in the following stages,
Interview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10D-49 DTC: P0488 (Flush code 45). . . . . . . . . . . . 10D-267
DTC: P0108 (Flush code 71) . . . . . . . . . . .
Trouble diagnosis with scan tool . . . . . . . . . . . 10D-56
10D-148
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . 10D-51 DTC: P0522 ((Flush code294). . . . . . . . . . . . 10D-262
DTC: P0523 ((Flush code294). . . . . . . . . . . . 10D-267
DTC: P0112 (Flush code 22). . . . . . . . . . . .
Precautions on handling Tech 2 . . . . . . . . . . 10D-60 10D-153 DTC: P0601 (Flush code 53). . . . . . . . . . . . 10D-272
How to use Tech 2. . . . . . . . . . . . . . . . . . . . . 10D-62
DTC: P0113 (Flush code 22). . . . . . . . . . . . 10D-158
How to use injector checker . . . . . . . . . . . . . 10D-87
DTC: P0117 (Flush code 23). . . . . . . . . . . . 10D-164
List of function checks. . . . . . . . . . . . . . . . . . 10D-88
DTC: P0603 (Flush code 54). . . . . . . . . . . . 10D-273
DTC: P0606 (Flush code 51/52) . . . . . . . . . 10D-274
DTC: P0611 (Flush code 34) . . . . . . . . . . . . 10D-275
different from general machine fault.
OBD system check. . . . . . . . . . . . . . . . . . . . . . 10D-89 DTC: P0612 (Flush code 34). . . . . . . . . . . . 10D-278
Diagnosis lamp illumination circuit system check10D-
91
Diagnosis lamp blinking circuit system check 10D-93
DTC: P0615 (Flush code 19). . . . . . . . . . . . 10D-281
DTC: P0650 (Flush code 77). . . . . . . . . . . . 10D-286
DTC: P1093 (Flush code 227). . . . . . . . . . . 10D-291
1. Early stage of fault;
Scan tool power supply circuit system check 10D-96 DTC: P1094 (Flush code 226). . . . . . . . . . . 10D-299

• As the fault occurs for a short period and singly,

Scan tool communication circuit system check. 10D- DTC: P1095 (Flush code 225). . . . . . . . . . . 10D-306
98 DTC: P1112 (Flush
( code 542) . . . . . . . . . . . 10D-314
Starting circuit system check. . . . . . . . . . . . 10D-101 DTC: P1113 ((Flush code 158). . . . . . . . . . . 10D-322 2
a customer often does not notice and miss it. In
Starting system check . . . . . . . . . . . . . . . . . 10D-106 DTC: P1173 (Flush code 542) . . . . . . . . . . . 10D-314
Fuel system check . . . . . . . . . . . . . . . . . . . 10D-109 DTC: P1261 (Flush code 158). . . . . . . . . . . 10D-322
List of trouble symptom . . . . . . . . . . . . . . . . . 10D-397
Intake system check . . . . . . . . . . . . . . . . . . 10D-111 DTC: P1262 (Flush code 159). . . . . . . . . . . 10D-330
Exhaust system check . . . . . . . . . . . . . . . . 10D-112 DTC: P1271 (Flush code 24). . . . . . . . . . . . 10D-338

this stage, customer’s complaint is indefinite

EGR control system check . . . . . . . . . . . . . 10D-113 Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . 10D-401
DTC: P1277 (Flush code 24). . . . . . . . . . . . 10D-343
QOS system check . . . . . . . . . . . . . . . . . . . 10D-116 DTC: P1278 (Flush code 24). . . . . . . . . . . . 10D-348
List of diagnostic trouble code . . . . . . . . . . . . 10D-120Engine hunting, rough idling . . . . . . . . . . . . 10D-404
DTC: P1282 (Flush code 24). . . . . . . . . . . . 10D-353
DTC: P0088 (Flush code 118). . . . . . . . . . . 10D-129 DTC: P1283 (Flush code 24). . . . . . . . . . . . 10D-358
DTC: P0089 (Flush code 151) . . . . . . . . . . 10D-133
DTC: P0091/P1291 (Flush code 247/248) . 10D-138
DTC: P0092 (Flush code 71) . . . . . . . . . . . 10D-140
Engine output shortage . . . . . . . . . . . . . . . . 10D-408
DTC: P128 5 (Flush code 16). . . . . . . . . . . . 10D-363
DTC: P128 5 (Flush code 416). . . . . . . . . . . 10D-367
DTC: P129 0 (Flush code 36). . . . . . . . . . . . 10D-373
and it is impossible to reproduce the trouble.
However, the engine control module (ECM)
DTC: P0107 (Flush code 71) . . . . . . . . . . . 10D-143 DTC: P1345 (Flush code 16). . . . . . . . . . . . 10D-363
DTC: P0108 (Flush code 71) . . . . . . . . . . . 10D-148 DTC: P1625 (Flush code 416). . . . . . . . . . . 10D-367
DTC: P0112 (Flush code 22). . . . . . . . . . . . 10D-153 DTC: P1630 (Flush code 36). . . . . . . . . . . . 10D-373
DTC: P0113 (Flush code 22). . . . . . . . . . . . 10D-158 DTC: P1631 (Flush code 55). . . . . . . . . . . . 10D-374
DTC: P0117 (Flush code 23). . . . . . . . . . . . 10D-164
DTC: P0118 (Flush code 23). . . . . . . . . . . . 10D-169
DTC: P0182 (Flush code 211). . . . . . . . . . . 10D-174
DTC: P1632 (Flush code 55). . . . . . . . . . . . 10D-377
DTC: P1633 (Flush code 55). . . . . . . . . . . . 10D-380
DTC: P1634 (Flush code 55). . . . . . . . . . . . 10D-383
may store the fault.
= Past fault (history trouble)
DTC: P0183 (Flush code 211). . . . . . . . . . . 10D-178 DTC: P1635 (Flush code 55). . . . . . . . . . . . 10D-386
DTC: P0192 (Flush code 245) . . . . . . . . . . 10D-183 DTC: U2104 (Flush code 84). . . . . . . . . . . . 10D-389
DTC: P0193 (Flush code 245) . . . . . . . . . . 10D-188 DTC: U2106 (Flush code 85). . . . . . . . . . . . 10D-393
DTC: P0201 (Flush code 271) . . . . . . . . . . 10D-193 List of trouble symptom . . . . . . . . . . . . . . . . . 10D-397

2. Middle stage of fault;

DTC: P0202 (Flush code 272) . . . . . . . . . . 10D-198 Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . 10D-401
DTC: P0203 (Flush code 273) . . . . . . . . . . 10D-203 Engine hunting, rough idling . . . . . . . . . . . . 10D-404
DTC: P0204 (Flush code 274) . . . . . . . . . . 10D-208 Engine output shortage . . . . . . . . . . . . . . . . 10D-408
DTC: P0205 (Flush code 275) . . . . . . . . . . 10D-213 Exhaust gas contains a lot of white smoke.. 10D-411

• The fault occurs for a short period and singly,

DTC: P0206 (Flush code 276) . . . . . . . . . . 10D-218 Exhaust gas contains a lot of black smoke.. 10D-414
DTC: P0219 (Flush code 543) . . . . . . . . . . 10D-223 Programming . . . . . . . . . . . . . . . . . . . . . . . . . 10D-416
DTC: P0237 (Flush code 32) . . . . . . . . . . . 10D-225 Rewriting of ECM (On-board)

TSWG0156
but repeats intermittently and definitely occurs
Name under a specific condition. A customer’s
1. Diagnosis for each DTC complaint (contents of the fault) is clear but
2. List of trouble symptom description of condition of the fault is not clear.
Therefore, it is possible to reproduce the trouble
if a mechanic could figure out the conditions.
= Intermittent trouble (intermittent)
3. Stage that fault is real;
• The fault occurs on a steady basis and a
customer’s complaint is realistic and clear.
Therefore, it is possible for a mechanic to
reproduce the fault. However, sometimes there
are multiple causes.
= Current fault (present trouble)
 Electronic control fuel injection system (Common rail type) 1E-13
Interview 2. All of complaints from customers do not always
mean troubles.
Interview
3. Extra repair steps are caused if the trouble
1. Comprehend the contents of a customer’s condition is not correctly reported to a mechanic in
complaint using “Check list (engine control charge.
system)”.
• The check list helps to diagnose, repair, and
<Reference>
recheck after repair work in the maintenance shop.
Do not interview blindly. Interview about the trouble
presumed by symptoms (cases).
2. Evaluate the trouble information correctly.
Figure out specifically based on 5W1H.
Example: The temperature is low, at the time of
starting, constantly, in the vicinity of the engine
portion, metallic noise, etc.

Points for interview

• What Trouble symptom

• When Date, time, frequency of
occurrence
• Where Road condition
• In what condition Running condition,
operating condition,
weather
• How Feeling about symptom

Check list for engine control system

It is necessary to confirm “Trouble symptom” and “Data
of occurrence of a trouble” based on check list (engine
control system) on receiving the machine from a
customer at a service shop.

TSWG0155

TSWG0160

Name
1. Trouble symptom
2. Frequency of trouble occurrence / trouble
conditions

Because:
1. It may be impossible to reproduce the trouble
symptom at a service shop.
1E-14 Electronic control fuel injection system (Common rail type)

TSWG0155
 Electronic control fuel injection system (Common rail type) 1E-15
Pre-inspection Trouble Diagnosis

Visual inspection of engine compartment About diagnostic trouble code (DTC)

Visual inspection of engine compartment should be Every time turning the key switch to ON, the ECM
carefully when performing the diagnostic procedure. performs self-test of most wiring and components and
This inspection can often solve the trouble with no extra stores the detected faults in memory. For some DTCs, it
steps. If performing visual inspection, follow the also performs the back-up control. If the fault which
guideline below. affects operation occurs, the diagnosis lamp comes on
• Check all the air hoses etc. for punch hole, cut, to notify an operator.
disconnection or improper routing.
• Inspect the hoses hidden behind other Basic knowledge for required tools
components. Important:
• Check if all the harnesses of the engine If performing the diagnostic procedure, no basic
compartment are properly connected, if there are knowledge on this powertrain may lead to faulty
any burnout parts or worn parts, if harnesses are diagnosis or damage to powertrain components. If
pinched, if there are any contacts with sharp you do not have basic knowledge, do not perform
edges, or an exhaust manifold or pipes in high the diagnosis of the trouble relating to powertrain.
temperature, etc. Basic understanding on hand tools, such as scan
tools, is required to utilize service manual
Machine maintenance result check effectively.
If the maintenance of the machine is not properly
About on-board diagnosis test
performed, the diagnosis lamp comes on. Clogging in
oil filter or fuel filter caused by insufficient oil change or Types of trouble diagnosis results are the following.
improper oil viscosity and deposit in crankcase may 1. History trouble
cause troubles on the machine, which were not found Trouble codes which occurred under the following
before on-board diagnosis (OBD) system check. conditions are called “History trouble”.
Though improper maintenance of the machine is not • Diagnostic test was completed at previous
classified as “The trouble caused by other than a ignition cycle.
machine”, a maintenance schedule should be more • Diagnosis test has accepted at current ignition
strictly followed because of high sensitivity of the on- cycle.
board diagnosis (OBD) system check.
• Faults found by the diagnostic test do not
currently exist.
Non-OEM parts
2. Present trouble
All the on-board diagnosis system checks are adjusted Trouble codes which occurred under the following
to be operated by genuine parts. Therefore, if a conditions are called “Present trouble”.
commercial general sensor or switch is installed, the
• Diagnostic test was completed at previous
diagnosis lamp comes on due to faulty diagnosis.
ignition cycle.
If commercial electronic devices, such as mobile
phone, stereo, antitheft device, etc. are installed and • The faults detected by the diagnostic test
their installation is not proper, EMI (electromagnetic currently exist.
interference) may be discharged to the control system. • The faults exist at current ignition cycle.
That leads to the generation of fault sensor information
and the diagnosis lamp comes on. When performing
trouble diagnosis, turn the power of all commercial Description of terms
parts to “OFF” or remove those parts, and check for
faults again. Ignition cycle
Ignition cycle is defined as Key ON, Run and Key OFF
so that the machine can be operated under the
Information: specified diagnostic standard.
Fault in related system
Diagnosis lamp
Many on-board diagnosis (OBD) system checks enter
the back-up operating mode by instruction from engine Basically, the diagnosis lamp comes on when a fault is
control module (ECM) when the ECM detects the fault detected in electronic control, such as engine control
in related systems or components. In the back-up module (ECM).
operating mode, they lower output to protect the
machine.
1E-16 Electronic control fuel injection system (Common rail type)
Data link connector (DLC) How to read DTC
The data link connector is communication device with
control unit. The DLC is also used to connect a scan How to read DTC by diagnosis lamp
tool. General use of scan tool is described below. The diagnosis lamp blinks to indicate the current and
history trouble codes (DTCs) stored in ECM by
Note: connecting the diagnosis switch.
The location of DLC and existence of DLC vary
depending on each machine. Refer to the Note:
machine’s manual. Refer to the machine’s manual for the locations of
diagnosis lamp.
• Identification of stored DTC
• Reading of serial data • Turn the key switch to ON and make sure the
diagnosis lamp illuminates. (Bulb check)
About ECM OFF • Turn the key switch to ON, and the engine OFF.
The power of ECM is cut off 10 seconds after the key • Connect the diagnosis switch (connector).
switch is turned to OFF, and then it will be ECM OFF • Read the blinking pattern of the diagnosis lamp.
condition. • Judge the contents of DTC by DTC table.
If a scan tool has been connected, it can be read using
Operation of comprehensive diagnosis for the tool.
monitors of components
It is necessary to comprehensively diagnose Indication with no DTC stored
components for the proper operation of the engine. The code “1”, which indicates starting of code display, is
repeatedly displayed.
Input components:
Input components are confirmed to check if there are Indication with DTC stored
open circuit and the values exceed the range. Stored trouble code is displayed three times. If more
Though the following does not include all input than one trouble code are stored, they are displayed in
components, these sensors are included. the ascending order for three times each. After taking a
• Crankshaft position (CKP) sensor round, codes are repeatedly displayed in the ascending
• Camshaft position (CMP) sensor order. This will last as long as the diagnosis connector
• Engine coolant temperature (ECT) sensor is connected.
• Vehicle speed sensor
• Boost pressure sensor
• Common rail pressure sensor
• Accelerator position (AP) sensor

Output components:
Output components are diagnosed if their responses to
commands from control units are relevant. Check
whether there are open circuit and the values exceed
the range.
Though the following does not include all the output
components to be confirmed, these circuits are
included.
• Suction control valve (SCV)
• Lamp, relay control
• Magnetic valve
• Diagnosis lamp
 Electronic control fuel injection system (Common rail type) 1E-17

At code [23]

t1=approx. 0.3 sec.

ON t2=approx. 0.6 sec.
t3=approx. 1.2 sec.
t4=approx. 2.4 sec.

Goes off

Tens digit Units digit

At code [413]

ON

Goes off

Hundreds digit Tens digit Units digit

About DTC indicated by blinking of diagnosis lamp If there is intermittent (intermittent trouble)
While the engine stops, both the current and past DTCs The trouble situation not occurring constantly is called
are displayed. intermittent (intermittent trouble). Perform the following
While the engine is operated, the lamp illuminates only steps to solve the intermittent trouble.
if the current DTC occurs. 1. Check the DTC information and data display.
2. Evaluate symptom and situation explained by the
How to read DTC by trouble display monitor
customer.
When a DTC occurs, it is displayed on trouble display 3. Check the circuits or the electric system
monitor on the machine. components using check sheet or other methods.
How to read DTC by a scan tool
If the trouble is not detected
DTC can be read using a scan tool.
In this case, the machine is judged as it operates
Note: properly. The condition explained by the customer may
Refer to “Trouble diagnosis with scan tool, be the normal condition. Confirm the customer’s
Operation procedure” for work procedure. complaint comparing with the condition of the machine
to that of another machine. That condition may mean
If the DTC (diagnostic trouble code) is stored an intermittent trouble. Confirm the complaint in the
situation the customer explains before returning the
Perform service correctly according to the specified machine to the customer.
DTC chart.
1. Confirm the complaint again.
If the complaint can not be fully detected or
If there is no DTC
identified, the machine must be diagnosed again.
Select symptom from the diagnostic chart according to Confirm the complaint one more time. The
symptom. Complete the service following diagnostic complaint may be an intermittent trouble as
procedure. You may also perform inspection by defined in “If there is intermittent”, but it may also
referring function diagnosis. be possible that the machine is normal.
2. Repair and confirm.
If there is no applicable symptom If the problem is confirmed, repair it. Confirm that
1. Confirm the complaint in detail. the machine operates properly and the symptoms
2. Create diagnostic plan. are corrected. This includes test on the machine or
3. Use wiring diagram and principle of operation. other procedures to confirm that the trouble is
Ask for technical support when repair history is solved under following conditions:
available for similar case. Connect technician’s • Confirm by testing in the situation that the
knowledge with the effective usage of available service customer described.
information. • If DTC is diagnosed, reproduce the situation
found while the DTC is set, and confirm the
repair by checking a scan tool data.
1E-18 Electronic control fuel injection system (Common rail type)
Confirmation after repair About confirmation of machine repair
It is effective for confirmation of machine repair to use
Confirmation of machine repair on-board diagnosis (OBD) system check. Mechanic
If an electronic control system is repaired, it is should perform the following steps to diagnose the
necessary to confirm that repair is properly performed machine after repair.
after the repair work. If this confirmation is not properly 1. Review and record the DTC (diagnostic trouble
performed, it may happen that the diagnosis lamp code) or scan tool data used in diagnosis.
comes on again or a trouble in operability occurs in the 2. Clear the DTC.
course of delivering the machine to the customer. 3. Operate the machine based on scan tool data.
Especially as for intermittent (trouble), it is needed to
4. Confirm the DTC status information of specified
reproduce and confirm the situation according to the
DTC used in diagnosis until the diagnostic test
customer’s complaint.
relating that DTC is performed by control unit.
In the case of confirmation of repair by on-board
diagnosis (OBD) system check, performing these steps
is extremely important. Failure to perform these steps
may require unnecessary repair.

List of final check items

No. Item Purpose Method

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

Confirmation of powerful electric wave transmitter; if • Do not install mobile communication equipment
faults are found in these items, inform a customer of the with high output.
following check items as required.
• An antenna should be installed as far away from Caution:
control unit/sensors or electrical systems on the If confirming repair using on-board diagnosis
machine as possible. system check, perform the following steps. If not
following these steps, unnecessary repair may be
• Antenna codes should be installed at least 20 cm
needed.
(7.8 in) away from control units/sensors or
electrical systems on the machine. • Review and record the scan tool data related to
DTC which is diagnosed.
• Do not put the antenna codes and other wire
together. Keep the antenna codes as far away from • Clear the DTC.
other wire as possible. • Operate the machine while checking the
• When installing an additional equipment, follow its relevant scan tool data.
installation manual to install it securely.
 Electronic control fuel injection system (Common rail type) 1E-19
How to clear DTC Clear with ECM (intermittent trouble)
The DTC stored in ECM will be cleared if the same one
Clear of DTC is not valid within 20 ignition cycles.
The DTC, which have been stored in the engine control
module (ECM) upon trouble occurrence, will not be
erased even if the faulty parts are repaired, unless it is
compulsory cleared in the following procedure.

Clear with a scan tool

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

Clear with memory clear switch

1. Turn the key switch to ON.
2. Turn the diagnosis switch to ON.
3. Turn the memory clear switch to ON.
4. Leave as it is ON for 3 seconds.
5. Turn the memory clear switch to OFF.
6. Turn the diagnosis switch to OFF.
7. Turn the key switch to OFF.
8. Leave as it is for 10 seconds.
9. Turn the key switch to ON.
10. Turn the diagnosis switch to ON.
11. Make sure that memory is cleared.

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16

TSWG0023

Note:
• Refer to the machine’s manual for the locations
of memory clear switch and diagnosis switch.
• Perform the same procedure to clear memory
regardless of forms of switches (switches,
connectors). (ON = Connection, OFF =
Disconnection)
1E-20 Electronic control fuel injection system (Common rail type)
Trouble diagnosis with scan tool
About scan tool
There are scan tools for each machine manufacturer
and the scan tool (Tech2) for Isuzu, and they have
different display method respectively.
The scan tools for the machine manufacturer with CAN
communication display only the physical value in data
parameters.

TSWG0185

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

communication can display both the physical value and
voltage value.
In some diagnostic charts, both the voltage value and
physical value may be shown. Refer to the voltage
value for Tech2 and the scan tools with KW
communication or the physical value for the scan tools
with CAN communication.

Value

TSWG0182

Name
1. Tech2 and scan tool with KW communication
2. Scan tool with CAN communication
 Electronic control fuel injection system (Common rail type) 1E-21
About scan tool display
Refer to the relevant page by each machine manufacturer for the difference of data display in KW or CAN viewed
from ECU.

Tech2, KW display CAN display

Engine Model (EEPROM) Engine Model
Engine Serial Number (EEPROM) Engine Serial Number
ECM Part No. (EEPROM) ECM Parts Number
Software ID (EEPROM) Software Identification
Q Resistance (EEPROM) Q adjustment data
QR Code (EEPROM) QR code
Starter Switch (On) —
Starter Switch (ST) —
EGR BLDC Position 1 —
EGR BLDC Position 2 —
EGR BLDC Position 3 —
Glow Relay Switch —
— Glow Signal
Accelerator Sensor 1 Act Accel position
System Voltage —
Main Relay Voltage —
— Battery Voltage
Intake Air Temperature Sensor —
Fuel Temperature Sensor —
Engine Coolant Temperature Sensor —
Idle Up Volume Sensor —
Barometric Pressure Sensor —
Differential Fuel Rail Pressure —
Differential EGR Valve Position Sensor —
Engine Speed Act. Engine Speed
Desired Engine Speed Request Engine Speed
Intake Air Temperature Intake Air Temperature
— Boost Pressure
— Boost Temperature
Engine Coolant Temperature Coolant Temperature
Fuel Temperature Fuel Temperature
Barometric Pressure Barometric Pressure
Engine oil pressure Engine Oil Pressure
— Fuel Flow
— Engine Torque
— Trip used fuel
— Total used fuel
Differential EGR Position (BLDC Motor) —
SCV Duty —
EGR BLDC Motor Duty —
1E-22 Electronic control fuel injection system (Common rail type)

Tech2, KW display CAN display

EGR DC Motor Duty —
SCV F/B —
Desired Idle Speed —
Common Rail Pressure F/B Mode —
Engine Mode —
Target Fuel Flow —
Main Fuel Injection Timing —
Pre-fuel Injection Amount —
Main Fuel Injection Amount —
 Electronic control fuel injection system (Common rail type) 1E-23
About scan tool (Tech2)
This is an useful tool to diagnose the electric faults and
the system check of the engine control system. The
Tech2 is small and light tester. It can communicate with
each control unit to perform various types of diagnosis
and test by connecting it to DLC equipped to the
machine using Tech2 adapter.

ECM control
DTC

Sensor output

Data Link Connector

Read DTC Actuator Test

V
V
RPM
RPM
Snapshot V
V
%

TSWG0121
1E-24 Electronic control fuel injection system (Common rail type)
Function of Tech2 • The trigger type allows to record the data of the
time when DTC is displayed.
Data display • The stored data can be replayed with a domestic
This displays conditions recognized and controlled by power supply.
ECM at each items.
The values of display items is described in typical data Programming
of Tech2 data list. Confirm the data history before replacement of ECM.
The contents of display items describe about data. (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
V appropriate parts for faults.
V When giving instruction to ECM from test screen, set
RPM
the select switch of the Tech2 adapter to “2” position.
RPM
V
Caution:
V
Each test may not performed if the machine, engine
%
MPa operation status, coolant temperature, vehicle
speed, switch status, gear position, etc. does not
meet conditions or if DTC is detected.

TSWG0098

This menu can be used to display the current data.

The display synchronizes with the status of the
machine or equipment.
• If the data display menu cannot be selected:
Trouble occurs on the cable between ECM and
DLC.
The position of select switch on Tech2 adapter is
wrong.
• If the abnormal fixed value is displayed:
[Example] The data display value of engine speed,
each sensor, etc. is fixed and different from actual
one. Move the connector or harness by hand. If the
display changes from fix to release, connection of
the connector is faulty, pin tip length is uneven, or
open or short circuit exists in the harness where
you have moved. Therefore, repair is necessary.
• When asterisk mark (*) is displayed in place of
numeric display;
The Tech2 software has problem.
If asterisk mark (*) is found on any of the data,
PCMCIA card must be version-upgraded.

Snapshot
To find the cause of trouble, perform this snapshot to
review the data.
• The snapshot can record the data list menu and
plot a graph.
• Utilizing this mode, reproduce and record the
conditions claimed by the customer to identify the
data fault.
 Electronic control fuel injection system (Common rail type) 1E-25

How to use trouble diagnosis-related tool

How to use Tech2

Components of Tech2

1 5

3 4

TSWG0148

Name
1. PCMCIA card 4. DLC cable
2. SAE 16/19 adapter 5. Tech2
3. Power cable
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)

1. Softkeys 3. Action keys (YES, NO, ENTER, EXIT)

While operating the Tech2, selection boxes appear They are used to execute the operation of Tech2,
on the upper part of the screen. The softkeys respond to instruction/question, and switch/move
correspond the selection boxes. They cannot be to each menu screen.
used unless the selection boxes are displayed. 4. Function keys (F0 — F9)
2. Selection keys (Arrow keys) They are used to execute a menu function in the
They are used to select the menu or switch the screen. These keys also correspond to F numbers,
display on the screen of Tech2. Selected part is such as “F0”, when they are displayed on the
highlighted in the screen. menu screen.
 Electronic control fuel injection system (Common rail type) 1E-27
5. Help key (?) Handling
Explanation of Tech2 function, which is being used • The Tech2 is “precision electronic device”. Handle
at the time when the key is pressed, is displayed with extreme care.
6. Control keys (PWR / SHIFT) • Operating voltage of Tech2 is DC 12 V. Do not
The PWR key turns on/off the power to the Tech2. energize 24 V to it.
The SHIFT key is used to adjust the screen
contract. When the SHIFT key is active, the orange
LED illuminates. In this case, all the keys except
selection keys and functions are locked. When the
power is on, the green LED illuminates.
7. Wide stand
Use this as a stand. The stand opens angle of 0 —
180°.
8. Display area (LCD)
This is liquid crystal display (LCD) with contrast
adjusting function. It displays ECM information and
various instructions.
9. Machine communication interface (VCI) module
This is a module to communicate between the
machine and Tech2.
10. Fastening bar of VCI module
The bar is used to install/fasten/remove the VCI.
11. Connector of DLC cable connection
TSWG0111
This is used to connect the Tech2 to the machine.
Connect the DLC cable. • Do not have an impact on it by dropping. It causes
12. Connector for AC adapter connection internal faults even no damage on appearance.
This is used to connect the attached AC adapter
when using Tech2 with other than the machine.
13. PCMCIA card insertion slot with cover
Open the cover when inserting the PCMCIA card
into Tech2. Insert the PCMCIA card with the cover
opened. Never insert/remove the PCMCIA card
when the Tech2 is powered on.
14. PCMCIA card release button
This is used to remove the PCMCIA card from
Tech2. Press the button to remove the PCMCIA
card. Never remove the PCMCIA card when the
Tech2 is powered on.
15. Connector for external communication (RS-232
port)
This is used to connect the Tech2 to a computer.
16. Connector for external communication (RS-485
port)
This is a connector for phone line connection,
TSWG0112
however it is not currently used. Do not connect
the phone line etc. to this connector. • Be sure to turn off the power of Tech2 when
installing/removing the PCMCIA card. Avoid
Precautions on handling Tech2 repetition of installing/removing the card as
possible. Otherwise, the card may be deteriorated.
Ventilation • Before turning on the Tech2, make sure that the
If performing inspection and test with engine running in cables and adapters are connected securely.
badly ventilated area, such as garage, ventilate • Do not disconnect the cables and adapters
sufficiently. In badly ventilated area, poisoning may connected to Tech2 while the key switch is ON or
occur due to inhaling colorless, odorless carbon the engine is starting.
monoxide included exhaust gas.
1E-28 Electronic control fuel injection system (Common rail type)
• Do not connect the phone jack to communication
port on the side of Tech2.

TSWG0115

• Avoid using and storing it in a place with extreme

TSWG0113
high or low temperature. Especially in summer, do
• Avoid using and storing it in dusty area. When not not leave it in the machine exposed to direct
using it, always put it in its case to prevent the sunlight.
adapter from getting dust.

TSWG0116

TSWG0114

• Avoid using and storing it in a place with rapid

changes of temperature. If bringing it from cold
outside into warm indoor suddenly, dew
condensation may occur resulting in malfunction or
trouble.
 Electronic control fuel injection system (Common rail type) 1E-29
• Avoid using and storing it in a place that it may Power supply
contact water or chemicals. When cleaning, use
cloth with mild detergent, not highly-volatile solvent About power supply
such as thinner, and wipe out using dry cloth. Its The power supply method for the Tech2 varies
display is easy to get dirty, clean periodically using depending on the voltage of the machine, shape of
antistatic cloth. DLC and the situation in which the unit is used.
Therefore the user will have to gain good
understanding of the relevant connecting procedure.
Notice that machine data and DTC will not be able to be
checked if the connection is not established in
accordance with the power supply of the machine.

Note:
Use of the external power (AC power) does not
allow to utilize the applications.

TSWG0117

Connection of power

TSWG0162

Name
1. Battery cable 2. Power socket cable (AC/DC adapter)
1E-30 Electronic control fuel injection system (Common rail type)
Battery cable Caution:
This cable should be used, in the case where no power If the card is not inserted properly and the unit is
is supplied even when the Tech2 is connected to the switched on, “NO PCMCIA CARD INSERTED” will
machine through the machine DLC cable, or where the appear. If that is the case, turn off the power and
machine works with a higher voltage than the operating redo the insertion of the PCMCIA Card.
voltage of the unit. When connecting the cable, pay
Connection
heed to the polarities of the clamps. (The black clip of
the cable is to be connected to the negative terminal of Check to see whether the DLC cable is fitted with an
the battery and the red clip to the positive terminal.) adapter compatible with the machine.

Caution: Note:
In the case of a 24-V machine, connect to battery on Before connecting the cable to the machine, verify
the body ground side to take out 12 V. that the key switch is in the “OFF” position.

Caution:
In the case of a 24-V machine, connect to battery on
the body ground side to take out 12 V.

How to connect Tech2

1. Insert the PCMCIA Card with the latest version of
ISUZU system into the Tech2.
2. Connect the SAE 16/19 adapter to the DLC cable.
3. Connect the DLC cable to the Tech2.
4. Make sure that the key switch is OFF.
5. Connect the SAE 16/19 adapter of Tech2 to the
machine DLC.

Caution:
Connecting method varies depending on each
machine. Refer to the machine’s manual. The
following description is for the machine with DLC.
TSWG0141

Power socket cable (AC/DC adapter)

This is used to check the captured data by operating
Tech2 away from the machine.

Caution:
Be sure to use the power socket cable adapted to
local standards. Otherwise, it may result in failure
of Tech2 or power socket cable due to different
voltage and current depending on regions.

Check items before use

VCI
Check to see whether the VCI module is securely
inserted and whether the fastening latch bar of the VCI
module is located on the left-hand end.
Attach the DLC cable and fasten it by tightening the two TSWG0118
lock screws.

PCMCIA Card
Check to see whether the slot (upper side) has this card
inserted with its “Tech2” label side up.
 Electronic control fuel injection system (Common rail type) 1E-31
6. Turn the ignition switch to ON and press the “PWR” If the test ends normally, “Pass” will appear and one
key of the Tech2. short sound will be heard.
7. Check the display of the Tech2. If the test ends abnormally, “Fail” will appear and three
short sounds will be heard.

Note:
• If the LED fails to come on, it means a
malfunction of the LED, not a malfunction of
the SHIFT key.
• Absence of sound means a malfunction of the
Sound Transducer*1, but the unit can be used
as is, without any problem.
*1. Sound Transducer: The sound is intended
to indicate the completion of a data setup or an
error in a setup.

TSWG0110

Caution:
Be sure to turn off the power of Tech2 when
installing/removing the PCMCIA card.

Operation procedure
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
INITIALIZING” message will appear. During this period,
POST (Power-On Self Test) is carried out, and if the TSGW0085
test ends normally, a sound will be issued at the
completion of the test. Simultaneously, the LED of the Pass: Normal
SHIFT key will momentarily come on. This is also Fail: Abnormal
meant to check the normality of the LED.
Note:
Only for UART, SCI, RTC, and CLKMEM in
particular, the test result may appear as “Fail”
without this meaning any trouble. For “Fail” above,
refer to “Tech2 Self Test in Tool Options”.

IRAM: Internal RAM

ERAM: External RAM
UART: Universal Asynchronous Receiver and
Transmitter
MCU: MC68332 Microcontroller
SYSTEM INITIALIZING
QSPI: Queued Serial Peripheral Interface
SCI: Serial Communication Interface
TPU: Time Processor Unit
RTC: Real-Time Clock
CLKMEM: Clock Memory
KEYPAD: Keypad

TSWG0084

Display of POST results:

1E-32 Electronic control fuel injection system (Common rail type)
Main Menu
If all the functions are normal after the Tech2 has been
switched on, the Start Up screen will open, displaying
the Version No. and the applicable model year, stored
on the PCMCIA card, to allow the user to verify the
V
information. After the Start Up screen has opened, V
pressing the [ENTER] key will cause the “Main Menu” RPM
to appear. The Main Menu offers 4 different RPM
applications to select from. The desired menu can be V
executed moving the highlight bar to it with the relevant V
function key or selection keys and pressing the %
[ENTER] key. MPa

TSWG0087

Name
1. TITLE AREA
2. MESSAGE AREA
3. DISPLAY AREA
4. Highlight bar
5. FULL TEXT AREA
6. SOFT KEY AREA

• TITLE AREA: Shows the item currently selected.

• MESSAGE AREA: Shows a supplementary
Press [ENTER]
explanation or instruction.
• DISPLAY AREA: Displays data parameters and
values (9 lines x 23 characters).
• FULL TEXT AREA: Shows details of the parameter
under the highlight bar.
• SOFT KEY AREA: The softkeys below the function
item display boxes are valid.

Main Menu
F0: Diagnostics
Allows the user to check data, including Tech2-
compatible DTC (Diagnostics Trouble Codes), Data
Display, Snapshot, Miscellaneous Tests, etc., by
selecting a machine ID and System.
• DTC: Shows the contents and situation of DTC
stored in the controller of the system.
• Data Display: Shows the input/output data to/from
the machine controller under test. Since the
TSWG0086 displayed data varies from a system to another, and
besides, most of the items do not have their
Screen composition: guidance standard values installed, it is necessary
The screen for data display is composed in the to first check what the displayed data means.
following manner.
 Electronic control fuel injection system (Common rail type) 1E-33
• Snapshot: Allows to record and display the data of • Tech2 Self Test: Performs troubleshooting on the
malfunctions occurred. The displayed data not only functions of the main unit.
includes the one corresponding to the moment when
a malfunction occurred, but also those that existed Caution:
before and after the occurrence of the malfunction. It While this function is under execution, do not
also provides the function (Plot) to draw graphs. connect the unit to the machine!
F1: Service Programming System (SPS) • Set Clock: Sets the internal clock of the Tech2.
• Set Unit: Switches between the Metric system and
Note:
the English system.
Except industrial engine.
• Set Contrast: Adjusts the brightness of the display.
F2: View Capture Data F4: Down Load Up Load Help
Allows to review data recorded under Snapshot of “F0: The function to upload/download data (DTC, Snapshot,
Diagnostics”. etc.) acquired through the Tech2 to/from a PC, and the
F3: Tool Options Help function to render assistance in case the operation
Offers the function to make settings for the Tech2 main encounters a hitch.
unit, to display POST (Power On Self Test) results, and
to perform detailed tests (PCB, VCI).

List of functions of Tech2

TSWG0161
1E-34 Electronic control fuel injection system (Common rail type)
Diagnostic procedure
1. When the Tech2 is switched on, the software
version and the model year applicable to the
software will also be shown. Confirm the display
and press [ENTER].

TSWG0089

4. Select the Vehicle Type on the “Vehicle

Identification” screen and press the [ENTER] key.

TSWG0110

2. Press the function key [F0] or bring the cursor to

[F0: Diagnostics] on the “Main Menu” screen by
operating the selection keys (▲▼). And then,
press the [ENTER] key.

TSWG0090

TSWG0088

3. Select the Model Year corresponding to the

desired diagnostic action on the “Vehicle
Identification” screen and press the [ENTER] key.

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
5. Press the function key [F0] or bring the cursor to
[F0: Engine] by operating the selection keys (▲▼).
And then, press the [ENTER] key.

TSWG0093

8. The following illustration shows the state in which

the Tech2 is waiting for communication with the
TSWG0091
machine controller. If the softkey “Next” is pressed
6. Select Powertrain (Eng. name) on the “Vehicle with the ignition key in “OFF”, this display will stay
Identification” screen and press the [ENTER] key. forever. (State of communication disabled)
However, turning the ignition key “ON” to “START”
in this condition will place the unit in the waiting
state for communication.

TSWG0092

7. The items chosen in steps 3 to 6 are shown in the

Message Area display section. If the identification TSWG0122
of the machine is OK, turn the ignition key “ON” to
“START” and press “Next” by following instructions 9. Once the communication is established, the unit
given on the screen. will show the part No. and DDI (Diagnostic Data
Identification) (which varies from a system to
Note: another). Press the softkey “Confirm” and go on to
If you make any mistake, pressing the [EXIT] key the application. If any mistake was made in the
will return you to the “Main Menu”. selection of the vehicle type, despite that the
communication is enabled, a message to that
effect will appear flashing. If that is the case, check
the vehicle type again and redo the operation from
step 1.
1E-36 Electronic control fuel injection system (Common rail type)
Depending on a machine, DTC is not clearing by
Tech2. (The memory clear harness on the machine side
needs to be connected to ground.)

DTC application menu display screen

[Example] Industrial Engine
F0: DTC Display
If no DTC stored

TSWG0094 d
Pressing [EXIT] key in the steps 3 to 9 will return you to
the “Main Menu” screen.

DTC check
1. Select “F0: Diagnostic Trouble Codes” on the
“Engine” screen.

TSWG0123

If DTC stored

TSWG0095

F0: Diagnostic Trouble Codes

This function allows the user to analyze the
information on the Trouble Code related to the TSWG0096
system currently under test.
2. Choosing “F0: Diagnostic Trouble Codes”, the
following menu is displayed.
F0: DTC Display
F1: DTC Clear
F0: DTC Display
Loads and displays the DTC information stored in the
machine controller in a priority order.
F1: DTC Clear
 Electronic control fuel injection system (Common rail type) 1E-37
Data Display Softkey functions
1. Select “F1: Data Display” on the “Engine” screen. A maximum of 5 data parameters can be fixed on the
F1: Data Display “Data Display” screen. The 5 fixed parameters will be
Displays the information concerning various parts retained at the upper part of the screen, even when the
of the engine and transmission as data on the display is scrolled up or down. To fix parameters, bring
screen of the Tech2. the highlight bar to the desired parameter on the
screen, which appears as you select the softkey “Select
Items”, and press the [ENTER]. The selected item can
be identified by the asterisk (*) which will be placed
atop the parameter. Move the highlight bar with the
selection keys (▲▼), and once you have chosen all the
parameters you want fixed, press the softkey “Accept”.
“Data Display” screen is displayed again. To modify the
fixed parameter list, choose “Select Items”, move the
highlight bar to the parameter you want changed, and
press the [ENTER] key. The parameter will be cleared.
Choosing “Clear All” will clear all the fixed parameters.

If you select the softkey “DTC” while the “Data Display”

function remains active, DTC will be displayed on the
“Data Display” screen.
Snapshot can be used while the “Data Display” function
remains active. For this, choose “Quick Snapshot.”
Choosing the softkey “More” allows to use additional
TSWG0097 functions.
For “Quick Snapshot,” refer to “Snapshot.”
2. F1: Choosing “Data Display”, the engine data is
displayed.

V
V
RPM
RPM
V
V
%
MPa

TSWG0098
1E-38 Electronic control fuel injection system (Common rail type)

V V
V V
RPM RPM
RPM RPM
V V
V V
% %
MPa MPa

TSWG0099

Snapshot Snapshot
1. Select “F2: Snapshot” on the “Engine” screen. Snapshot is intended to save information received by
the machine controller during its execution. It provides
an effective means to analyze data generated when the
machine encounters a trouble. Use of this function
enables the user to focus on the situation in which the
trouble took place, without having to view all the data
for suspected malfunctions. The Tech2 is capable of
holding two different Snapshot data. This ability of
storing two different Snapshot data allows to compare
Good and Bad machine states with each other. Since
these data are saved on a first-in, first-out basis, the
first Snapshot data (of older date/time) stored on the
PCMCIA card will be lost as it is overwritten when a
third data comes in. Therefore, be sure to set the
internal clock of the Tech2 precisely before starting the
Tech2. If a given data must not be erased, highlight that
data and choose the softkey “Write Protect”. This
prevents the data from being overwritten. Pressing the
softkey “Clear” cancels the protect.
TSWG0100
Snapshot is available in the following 2 types:
2. Choosing “F2: Snapshot”, the following menu is
• Snapshot: To be chosen in the Snapshot Menu.
displayed.
F0: Manual Trigger • Quick Snapshot: To be chosen through the softkey
F1: Any Code on the “Data Display” screen.
F2: Single Code The Snapshot Data will not be lost even when the
F4: Beginning Tech2 is switched off, because the data is saved on the
F5: Center PCMCIA card.
F6: End
About trigger type:
Choosing the Trigger Type Menu allows to check the
cause that triggered [Snapshot]. [Snapshot] is executed
when there is one of the three causes of occurrence.
F0: Manual Trigger:
Pressing the softkey “Trigger” saves data.
 Electronic control fuel injection system (Common rail type) 1E-39
F1: Any Code: 2. Move the highlight bar to the data you want
Data is saved in case any trouble code is issued. replayed, and press the [ENTER] key. The data will
be replayed.
F2: Single Code:
Data is saved in case the specified trouble code is
issued.

About trigger point:

Trigger Point corresponds to the point in time where
triggering is originated by a code issued or by Manual
Trigger activated. This information is useful to know the
time point of Snap Point and to investigate changes in
the data parameter. Trigger Point can be set up at
“Beginning”, “Center”, or “End.”
F4: Beginning
Starts saving data from Trigger Point, and keeps on
saving it, until the Snapshot recording area is filled up.
This selection is effective when the trouble that
constitutes the cause is foreseeable.
F5: Center
This function is commonly utilized, since it saves not
TSWG0102
only the data after Trigger Point, but also those prior to
that. This selection allows to compare data that existed Note:
before the occurrence of a trouble, those present at the Flashing “Trigger” means that data is being
time of occurrence of the trouble, and those after the recorded. Pressing the [EXIT] key in this condition
trouble, among themselves. will abort the recording. The recording will also be
F6: End cancelled when the memory capacity is filled up. In
Saves only the data prior to Trigger Point. This either case, the data is saved in memory.
selection is useful when it is desired to terminate
Snapshot after the occurrence of a trouble. Plot
Snapshot can also be replayed in “View Captured
Snapshot data replay Data.”
1. Press the softkey “Review Data” on the “Snapshot
Options” screen. Plot setup procedure
1. Pressing the softkey “Plot” switches the “Data
Display” screen.

RPM
MPa

V
V
RPM
V
V
%

TSWG0101

TSWG0103
1E-40 Electronic control fuel injection system (Common rail type)
2. Bring the highlight bar to the parameter you want Explanation of Plot data displayed
plotted in a graph, as with “Select Items”, and
press the [ENTER] key.
E
3. The selected parameter can be identified by the
asterisk that appears at its top. No more than 3
parameters can be displayed. A

C
TSWG0106

A: Maximum values of selected parameters

B: Minimum values of selected parameters
C: Values of selected parameters and Center Point (E)
in frame
TSWG0104
D: Number of frames/time
4. Choosing the softkey “Accept” changes the display E: Center point of graph indication
screen and shows a graph after a while.

TSWG0124

TSWG0105
1. Denotes recognition of DTC.
Plot cancel A vertical line appears in abscissa, if there is a
Trouble Code issued in the Snapshot Data loaded.
To close the graph display screen, press the [ENTER] When plotting a graph, it is advisable to check for
key and you will be returned to the “Data Display” DTC through “Over View”.
screen.
2. DTC-recognized frame 236 (Actually issued in
Frame 235.)

Softkey functions
Choose the “More” on the snapshot graph display
screen.
• Move ← : Allows to view changes of data
preceding the display screen.
 Electronic control fuel injection system (Common rail type) 1E-41
• Move → : Allows to view changes of data following 2. Pressing the softkey “Select Frame” causes the
the display screen. following screen.
• Trigger Frame: Displays a trigger point.
• More: Switches the displayed softkeys.
Choose the “More” on the plot display screen.
• Zoom In: Shows the abscissa by enlarging it (each
press doubles the display).
• Zoom Out: Shows the abscissa by reducing it
(each press halves the display).
• Over View: Shows the entire frame.
• More: Switches the displayed softkeys.
Choose the “More” on the plot display screen.
• Time / Frame conversion: Switches the value in
abscissa.
• More: Switches the displayed softkeys.

Select frame
Select frame setup procedure
TSWG0125
1. Press softkey “Select Frame.”
• First Frame: First frame No. and data acquisition
time from Trigger Point (calculated backward).
• Last Frame: Last frame No. and data acquisition
time from Trigger Point (integrated).
RPM • Go To Frame: Entering a frame No. allows to view
MPa its data.
• +/-: Only the “-” sign is displayed.
V 3. “1” entered via keys in the “Go To Frame” area.
V
RPM
V
V
%

V
V
RPM
RPM
TSWG0103
V
V
%
MPa

TSWG0107

Frame No. 1 and recording time displayed, and data

values in Display Area represent those of Frame 1.
1E-42 Electronic control fuel injection system (Common rail type)
Actuator test 4. Select the Rail Pressure Test.

TSWG0127 TSWG0130

Common rail pressure control test

This test is performed to check the operation of RPCV.
The Tech2 must be used in this test.
Test procedure
1. Connect the Tech2 to the machine DLC.
2. Start the engine and run it at idle.
3. Select the Common Rail System.

TSWG0146

TSWG0128
 Electronic control fuel injection system (Common rail type) 1E-43
5. Send the instruction to RPCV and check the data Injector balance test
list.
This test is performed to confirm that proper electric
signal is sent to injector while the engine is running.

Note:
At test, the engine is controlled to low idle speed, in
order to clarify the variation of engine speed.

Test procedure
RPM
MPa 1. Connect the Tech2 to the machine DLC.
2. Start the engine and run it at idle.
3. Select the Common Rail System.
4. Select Injection Stop for Each Injector.

TSWG0147

6. If variation of data list is proper value, RPCV is

judged as normal.

TSWG0138

5. Send instruction to each injector (set to OFF by

softkey on Tech2 screen) to stop the injector, and
check the variation of engine speed.

V
V
RPM
RPM
V
V
%

TSWG0139
1E-44 Electronic control fuel injection system (Common rail type)
6. If the engine speed varies when the injector stops, 6. If the operation sound is heard, electrical circuit of
electrical circuit of that injector is judged as normal. that injector is judged as normal.
If the engine speed does not vary when the injector If the operation sound is not heard, electrical circuit
stops, electrical circuit of that injector or injector of that injector or injector body is judged as faulty.
body is judged as faulty.
Note:
Injector control test After injector control test, the key switch must be
This test is performed to confirm that proper electric turned to OFF once to restart.
signal is sent to each injector. The Tech2 must be used
Glow time relay test
in this test.
Test procedure This test is performed to check the operation of QOS
1. Connect the Tech2 to the machine DLC. lamp.
The Tech2 must be used in this test.
2. Turn the key switch to ON (engine is standstill).
Test procedure
3. Select the Common Rail System.
1. Connect the Tech2 to the machine DLC.
4. Select Compulsory Drive of Injector.
2. Turn the key switch to ON.
3. Select the Device Control.

TSWG0131

5. Send instruction to each injector (set to ON by TSWG0137

softkey on Tech2 screen), and check the operation
sound of injector. 4. Select the Glow Plug Relay.

V
V
RPM
RPM
V
V
%

TSWG0133
TSWG0132
 Electronic control fuel injection system (Common rail type) 1E-45
5. Send the instruction to glow plug relay and check 5. Send the instruction to EGR valve and check the
whether the lamp on the machine operates. data list.

%
%
%

TSWG0134 TSWG0135

6. If the lamp operates properly, it is judged as 6. If variation of data list is proper value, EGR valve is
normal. judged as normal.

EGR regulating valve test View captured data.

This test is performed to check the operation of EGR The Snapshot data acquired through the application
valve. menu “F2: Snapshot” under the “Main Menu, F0:
The Tech2 must be used in this test. Diagnostics” can be replayed.
Test procedure Since the data is saved on the PCMCIA card, it can be
1. Connect the Tech2 to the machine DLC. viewed after disconnecting the Tech2 (DLC) from the
2. Start the engine and run it at idle. machine. Two data items can be saved there. The
3. Select the Device Control. internal clock of the Tech2 needs to be set precisely,
since the data are identified with dates and times.
4. Select the EGR Control.
Sample use of snapshot data replay
1. Turn on the power.

TSWG0140

TSWG0110
1E-46 Electronic control fuel injection system (Common rail type)
2. Press [ENTER]. 5. Press the softkey “Continue” on the display screen.

TSWG0108 TSWG0126

3. Choose “F2: View Capture Data” and press the 6. Snapshot Replay Screen appears.
[ENTER] key. “View Captured Data” appears.
4. Choose “Snapshot Data” with selection keys (▲▼)
and press the [ENTER] key.

V
V
RPM
RPM
V
V
%
MPa

TSWG0107

Softkey functions
TSWG0109 1. Choose the softkey “More” on the Snapshot
Replay screen
• Select Items: Chosen to fix and display a
parameter (up to 5 parameters).
• Plot: Draws a graph (Up to 3 parameter items).
• Select Frame: Allows to specify a frame No.
and to move a parameter to the specified frame.
• More: Switches the displayed softkeys.
2. Choose “More” out of the 4 softkeys on the display
screen.
• Auto Reverse: Allows to view changes of data
of each frame.
• Stop: Stops a frame in motion.
• Auto Forward: Allows to view changes of data
of each frame.
• More: Switches the displayed softkeys.
 Electronic control fuel injection system (Common rail type) 1E-47
3. Choose “More” out of the 4 softkeys on the display Tool option menu
screen. F0: Tech2 Self Test
• First Frame: Allows to view the top data frame. Allows to conduct a test that assists with the
• Trigger Frame: Allows to view a triggered diagnostics of the Tech2 itself. Normally the Self Test
frame. function need not be executed, since the Tech2
• Last Frame: Allows to view the last data frame. conducts the Power On Self Test (POST) every time it
• More: Switches the displayed softkeys. is switched on. If the POST demonstrates any trouble,
the results of the POST can be checked choosing the
4. Choose “More” out of the 4 softkeys on the display
Self Test menu.
screen.
• Units: Changes the unit (speed/temperature). F1: Set Clock
• Previous Frame: Allows to view changes of Resets the date and time of the Tech2. Before exiting
data by reversing it, frame No. by frame No. this menu, press the softkey “Set Clock” to save the
settings.
• Next Frame: Allows to view changes of data by
feeding it forward, frame No. by frame No. F2: Set Unit
• More: Switches the displayed softkeys. Switches the unit between the English and the Metric
5. Choose “More” out of the 4 softkeys on the display system.
screen. F3: Set Contrast
• DTC: Shows the frames in which a Trouble Changes the screen contrast (lighter or darker). The
Code was issued, in the range from the top change will be saved even after the Tech2 is switched
frame to the displayed frame. off.
• Previous DTC-Chg: Shows the frames in which
Tech2 self test menu
a Trouble Code was issued, in the range before
the displayed frame. F0: Automated Main PCB and VCI
• Next DTC-Chg: Shows the frames in which a Automatically executes function tests on the Main PCB
Trouble Code was issued, in the range after the and VCI modules.
displayed frame. F1: Automated Main PCB
• More: Switches the displayed softkeys. Automatically executes function tests on the Main PCB
6. Choose “More” out of the 4 softkeys on the display module.
screen. F2: Automated VCI
The Snapshot Replay screen is restored. Automatically executes function tests on the VCI
module.
Difference in operation of Snapshot Data Replay:
The operations of Snapshot Data Replay under “F2: F3: Selectable Main PCB
View Captured Data” are somewhat different from Allows to check detailed information on the PCB
those of Replay (softkey function “Review Data”) under module test items.
“F2: Snapshot”. Be careful not to confuse them. F4: Selectable VCI
Allows to check detailed information on the VCI module
Tool options test items.
Tool Options is the function to conduct a detailed test, in F5: Power On Self Test Results
case communication cannot be established with the Displays POST test results again.
machine at the time of setup of the Tech2 or at the time
of Power On Self Test (POST). 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
operating the selection keys (▲▼), and press the
[ENTER] key.

Note:
Each press on the [ENTER] key will increment the
numeric value one by one, but it will not exceed the
preset maximum value.
1E-48 Electronic control fuel injection system (Common rail type)
4. After all the values have been entered, press the Rewrite setting of Q adjust data by Tech2
softkey “Set Clock” and the changes will be saved.
“Q adjust, Injector code label” is attached to the cylinder
head cover. It is used for rewriting and registering the
ID.

1 2 3 4

TSWG0144

Set units
TSHK0098
Operation procedure:
1. Choose the “F2: Tool Options” and press [ENTER]. Name
2. Choose the “F2: Set Unit” and press [ENTER]. 1. Engine number
2. Typical engine model
3. Display the “Set Unit” screen, and move the cursor
3. Q adjust information
to the item you want changed by operating the
4. Injector information
selection keys (▲▼), and press [ENTER] key.
4. When the setup is complete, press the [EXIT] key 1. Refer to the following instruction for how to setup
to save the current setting. the Q adjust data.
Step 1
Note:
• Press [ENTER].
It will take effect next time the Tech2 is switched on.

TSWG0110
TSWG0145

* Metric
Temperature: °C Speed: km/h
* English
Temperature: °F Speed: MPH
 Electronic control fuel injection system (Common rail type) 1E-49
Step 2 Step 4
• Choose the menu F0: Diagnostics with ▲, ▼ (up/ • Choose the menu (Off-Road) Industrial Engine
down) keys or F0 (function) key, and press with ▲, ▼ (up/down) keys, and press the [ENTER]
[ENTER]. key.

TSWG0088 TSWG0090

Step 3 Step 5
• Choose the menu (5) 2005 with ▲, ▼ (up/down) • Choose F0: Engine in Menu with ▲, ▼ (up/down)
keys, and press the [ENTER] key. keys or F0 (function), and press [ENTER].
* Applicable for 2000MY or later.

TSWG0091
TSWG0089
1E-50 Electronic control fuel injection system (Common rail type)
Step 6 Step 7-1
• Choose “6HK1-TC (C/Rail_TIER3)” with ▲, ▼ (up/
down) keys, and press [ENTER].

TSWG0122

Step 8
TSWG0092
• Press the softkey “Confirm”.
Step 7 • This displays the ECU ID information.
• Press the softkey “Confirm”.
• The ignition is ON at this time.

TSWG0094

TSWG0093
 Electronic control fuel injection system (Common rail type) 1E-51
Step 9 Step 11
• Choose the menu F4: Programming with ▲, ▼ (up/ • Choose the menu F2: Service mode with ▲, ▼ (up/
down) keys or F4 (function) key, and press down) keys or F2 (function) key, and press
[ENTER]. [ENTER].
F0: Uploads the three-point Q adjust data
stored in the ECM to the Tech2.
* Registers the data when replacing ECM.
F1: Writes the three-point Q adjust data
temporarily stored in the Tech2 to the ECM.
* Registers to the ECM after replacing
ECM.
F2: Any data can be written. However,
password and ID are required.

TSHK0050

Step 10
• Choose the menu F0: Q adjust with ▲, ▼ (up/
down) keys or F0 (function) key, and press
[ENTER].

TSHK0052

Step 12
• Password input screen
• This procedure will end automatically if the
registration is not completed within 120 seconds.
The message “Time Over” appears.

TSHK0051

TSHK0053
1E-52 Electronic control fuel injection system (Common rail type)
Step 12-1 Step 13-1
• After entering the password, press the [ENTER] The numbers will appear on the screen. Obtain the ID
key. code from the machine manufacturer’s service center
• The password for 4/6HK1 is “SLNPTL4”. or Isuzu Industrial Engine Dept. service section by
using this number (6855 in this case).
• The password for 6WG1 is “SLNPTL6”.
Enter the obtained ID code (2495 in this case).
• Entering wrong password will return to the previous
menu. Note:
The ID code you have entered will appear on the
screen, suffixed with “0”.
The clock of Tech2 must be correctly set.

• After entering, press [ENTER] key.

TSHK0054

Step 12-2
• If the password you have entered is correct, press
the softkey [Okay].
• Enter the password within 120 seconds. Failure to TSHK0057
enter the password within 120 seconds will return
to Step 11. Step 14
• When the ID code matches, the following screen
will appear.
Press the softkey “Next”.
• This step can be performed only when the engine
speed is 0 rpm.

TSHK0055

Step 13
• After completing the password registration,
proceed to ID registration.
TSHK0058
 Electronic control fuel injection system (Common rail type) 1E-53
Step 15 Step 15-2
• Displays the three-point Q adjust data in the ECM. • If the Q adjust data you have entered is correct,
1. To modify the Q adjust data, press the softkey press the softkey “Program”.
“Change”.

TSHK0100

TSHK0059
Step 15-3
Step 15-1 • If the Q adjust data you have entered is off the set
• If the Q adjust data you have entered is correct, value, the message shown as Step 15-4 appears.
press [ENTER] key.
1. The entry conditions are as follows.
Conditions:
C/Rail system entry setting is “1 − 15”.
TIS system entry setting is “1 − 8”.

TSHK0101

TSHK0099
1E-54 Electronic control fuel injection system (Common rail type)
Step 15-4 Step 16
• To go to Step15-5, modify the Q adjust data within • When the writing of data completes, the following
the set value and press the softkey “Program”. screen will appear.
This indicates that the result of comparison of
entered data with that written in the EEPROM of
the ECM is in good condition.

TSHK0102

Step 15-5
• If the entered values meet the conditions in Step TSHK0104
15-1 and 15-3, the status display of data
registration (writing) from the Tech2 to ECM as Step 16-1
shown below will appear. • If the entered Q adjust data in Step 15-1 does not
correspond to that written in the EEPROM of the
ECM, the following message will appear.
Pressing the softkey [End] returns you to Step 11.

TSHK0103

TSHK0105
 Electronic control fuel injection system (Common rail type) 1E-55
Injector ID code (No. 1 cylinder − No. 6 Note:
cylinder) registration setting using Tech2 Do not enter the six figures “0”, indicated with
strikethrough in the illustration, of ID code on the
“Q adjust, Injector code label” is attached to the cylinder injector ID plate.
head cover. It is used for rewriting and registering the
ID.

1 2 3 4

TSHK0098 Name
Name 1. Injector ID plate
1. Engine number 2. Injector ID code
2. Typical engine model 3. Injector
3. Q adjust information
1. Refer to the following instruction for how to register
4. Injector information
Injector ID code.
There is the injector code on the top of injector as well. Step 1
When replacing the injector, register its code. • Press [ENTER].

TSWG0110
1E-56 Electronic control fuel injection system (Common rail type)
Step 2 Step 4
• Choose the menu F0: Diagnostics with ▲, ▼ (up/ • Choose the menu (Off-Road) Industrial Engine
down) keys or F0 (function) key, and press with ▲, ▼ (up/down) keys, and press the [ENTER]
[ENTER]. key.

TSWG0088 TSWG0090

Step 3 Step 5
• Choose the menu (5) 2005 with ▲, ▼ (up/down) • Choose F0: Engine in Menu with ▲, ▼ (up/down)
keys, and press the [ENTER] key. keys or F0 (function), and press [ENTER].

TSWG0089 TSWG0091
 Electronic control fuel injection system (Common rail type) 1E-57
Step 6 Step 7-1
• Choose 6HK1-TC (C/Rail_TIER3) with ▲, ▼ (up/
down) keys, and press [ENTER].

TSWG0122

Step 8
TSWG0092
• Press the softkey [Confirm].
Step 7 • This displays the ECU ID information.
• Press the softkey “Confirm”.
• The ignition is ON at this time.

TSWG0094

TSWG0093
1E-58 Electronic control fuel injection system (Common rail type)
Step 9 Step 11
• Choose the menu F4: Programming with ▲, ▼ (up/ • Choose the menu F1: ID code registration with ▲,
down) keys or F4 (function) key, and press ▼ (up/down) keys or F1 (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.

TSHK0050

Step 10
• Choose the menu F1: Injector ID code with ▲, ▼
(up/down) keys or F1 (function) key, and press
[ENTER].

TSHK0067

Step 12
• Press the softkey [Next].
• As an example, the vehicle will be checked
whether it is in the condition (engine stopped) that
the ECM requests during ID registration.

TSHK0108

TSHK0068
 Electronic control fuel injection system (Common rail type) 1E-59
Step 12-1 Step 12-3
• The following display appears while checking if the • You need to enter the ID on the following display.
engine speed is 0 rpm. ID code is number of year. The following conditions
When the engine speed is 0 rpm, it will take you to must be met.
Step 13. Conditions:
1. The time setting of Tech2 matches with the
calendar.
2. Press the function keys (F0 — F9) to enter.

TSHK0069

Step 12-2

TSHK0071

Step 13
• Choose the cylinder (No. 1 cylinder − No. 6
cylinder) you want to register the ID code with ▲,
▼ (up/down) keys, and press the [ENTER] key.
• As an example, this describes about No. 1 cylinder.

TSHK0070

TSHK0072
1E-60 Electronic control fuel injection system (Common rail type)
Step 14 4. For VC17 (China), BCC code needs to be
• To register the ID code, press the softkey entered. NK3 request
[Change]. • Tech2 calculates the entered data and displays
• The ID code for Cylinder1 (No. 1 cylinder) selected the following message.
at Step 13 is shown here. • When entered ID code (QR) is out of the set
value:
Writing unable
• When entered BCC code is out of the set
value:
Writing unable
• When the ID code (QR) does not correspond
to BCC code:
Writing unable

TSHK0073

Step 15
• ID code registration (data entry)
1. The cursor is positioned at M (model code) in
the default setting.
MCD0 D1D2
2. At this point, enter the model code (MC) and ID
TSHK0074
code (D0) in this order.
• Entering with the function keys (F0 − F9) will
automatically move the cursor to the right.
However, if you enter with ▲, ▼ (up/down)
keys, you need to move the cursor with the
arrow (left/right) keys.
3. Entered data must be within $00 − $FF.
• You can enter 0 — 9 with the function keys (F0
− F9), or 0 — Z with ▲, ▼ (up/down) keys.
 Electronic control fuel injection system (Common rail type) 1E-61
Step 15-1 Step 15-3
1. The model code (MC) for VC25 is $5A, the Tech2 • If you have entered incorrectly (D7:$EG), do the
specifies to register (write) $5A automatically. following.
However you may also enter. 1. After pressing [ENTER] key as with Step 15-1,
Tech2 calculates the BCC code (BC) and registers press the softkey [Program]. This cause the
automatically. error message “Invalid data − Try again!” to
Therefore, you do not need to enter. appear.
2. After entering the ID code input data byte (MC-D9), 2. Set the data entry limit judgment.
press [ENTER] key. Judgment condition: Data (1 byte) meets the
following condition.
MSB:$F ≥ Data ≤ LSB:$F
• The following error message will be displayed
until the value that meets the condition is
entered.

TSHK0075

Step 15-2
• If the ID code you have entered is correct, press
the softkey [Program].
If you want to quit the program (registration), press
the softkey [Abort] or press [EXIT] key. TSHK0077

• Quitting the registration or pressing [EXIT] key Step 16

returns you to Step 11. • If the entered values meet the conditions in Step
15-1 and 15-3, the status display of data
registration (writing) from the Tech2 to ECM as
shown below will appear.

TSHK0076

TSHK0078
1E-62 Electronic control fuel injection system (Common rail type)
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
following 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
registration 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.

TSHK0080
 Electronic control fuel injection system (Common rail type) 1E-63
ID code upload (Tech2) Step 12
Step 11 • Pressing the softkey [Yes] updates the ID codes of
No. 1 cylinder − No. 6 cylinder stored in the ECM,
• This step 11 describes ID code registration
to the Tech2.
continued from the step right before.
Pressing the softkey [No] returns you to Step 11
1. Choose the menu F2: ID code upload (Tech2) without uploading the data.
with ▲, ▼ (up/down) keys or F2 (function) key, • Upload is the function to transfer the registered ID
and press [ENTER]. code from ECM to Tech2 to store the data in it.

TSHK0060
TSHK0062

Step 11-1
Step 12-1

TSHK0061
TSHK0061
1E-64 Electronic control fuel injection system (Common rail type)
Step 12-2 Step 12-4
• When the ID code registered in the ECM • Pressing the softkey [Confirm] returns you to Step
corresponds to that uploaded to the Tech2, the 11.
following message will appear.
Upload is completed.
Pressing the softkey [Confirm] returns you to Step
11.

TSHK0065

TSHK0063

Step 12-3
• When the ID code registered in the ECM does not
correspond to that uploaded to the Tech2, the
following message will appear.
Pressing the softkey [Confirm] returns you to Step
11.
• In this case, the uploaded ID code will be erased.
Therefore, perform upload again. The message
shown in Step 12-4 will appear.

TSHK0064
 Electronic control fuel injection system (Common rail type) 1E-65
ID code download (Tech2) Step 12
Step 11 • Press the softkey “Confirm”.
• This step 11 describes ID code registration • As an example, the vehicle will be checked
continued from the step right before. whether it is in the condition (engine stopped) that
the ECM requests during ID registration.
1. Choose the menu F3: ID code download (ECM)
with ▲, ▼ (up/down) keys or F2 (function) key,
and press [ENTER].

TSHK0090

Step 12-1
TSHK0088 • The following display appears while checking if the
engine speed is 0 rpm.
Step 11-1
When the engine speed is 0 rpm, it will take you to
Step 13.

TSHK0089

TSHK0091
1E-66 Electronic control fuel injection system (Common rail type)
Step 12-2 Step 13-1
• The following display appears when the engine • Registration is started from No. 1 cylinder (INJ.#1)
speed is not0 rpm. to No. 2 cylinder (INJ.#5) and the ECM in the order.
In this case, stop the engine as instructed in the The status for registration (writing) of data to ECM
message, and try again from Step 1. will appear.
The message in the screen changes in the order of
No. 1 cylinder (INJ.#1) and No. 2 cylinder (INJ.#5).
When it is abnormal, the registration repeats 3
times.

TSHK0092

Step 13
• Pressing the softkey [Yes] downloads (registers)
the uploaded ID codes (Cyl.1-Cyl.6) to the ECM. TSHK0094
Pressing the softkey [No] returns you to Step 11.
• Download is the function to register (write) the Step 13-2
stored (uploaded) ID codes (No. 1 cylinder − No. 6 • When the downloaded ID code corresponds to that
cylinder) in the Tech2 to the ECM. ID is registered registered (written) in the ECM, the following
from No. 1 cylinder to No. 6 cylinder in the order. message will appear. Download (registration) is
completed.
Pressing the softkey [Confirm] returns you to Step
11.

TSHK0093

TSHK0095
 Electronic control fuel injection system (Common rail type) 1E-67
Step 13-3
• When the downloaded ID code does not
correspond to that registered (written) in the ECM,
the following message will appear.
Pressing the softkey [Confirm] returns you to Step
11.

TSHK0096
1E-68 Electronic control fuel injection system (Common rail type)
How to use TIS 2000

TIS 2000 installation procedure

(Time needed: 30 minutes)

System Requirements 1. PC Free hard disk space: 150MB or more

OS: Windows 95 or higher RS-232C connector
CD-ROM drive
2. Distribution CD-ROM

* Internet Explorer version 4.01 or later is required to use TIS 2000.

* If Internet Explorer prior to version 4.01 is installed, or it is not installed on your PC, Internet Explorer version 4.01
(English version) will be installed automatically.

1. Turn on the power to start-up Windows. 5. Select the language to be used, and click the
2. Insert the distribution CD-ROM into the CD-ROM “Next”.
drive of PC.
3. The following screen will appear in approx. 10
seconds.
* If the screen does not appear, open the file of
“Autorun.Exe” in the CD-ROM.
4. When the “Welcome” screen appears, click the
“Next”.

6. Usually, leave the “Destination Directory” as it is,

and click the “Next”.
 Electronic control fuel injection system (Common rail type) 1E-69
7. On the “Choose serial port for Techline.” screen,
select the serial port of the serial cable to connect
Tech2 to the PC.
Normally, select the “COM1” and click the “Next”.

10. On the “TIS 2000 installation mode”, select the

“Standalone” and click the “Next”.

8. On the “Set HARDWARE_KEY” screen, select the

“LPT” and click the “Next”.

9. On the “Salesmake” screen, select either the

“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-70 Electronic control fuel injection system (Common rail type)
11. On the “TIS 2000 Update” screen, click the “OK”. This describes about how to transmit and display Tech2
snapshot data using the “Snapshot Upload” function of
TIS 2000. Snapshot data can be displayed with the
“Snapshot Upload” function of TIS 2000. The trouble
symptom can be checked by analyzing snapshot data
with various methods. To display the snapshot data,
perform the following 3 steps;

A. Record the snapshot data in Tech2.

B. Transmit the snapshot data to PC.

After recording the snapshot data to Tech2, transmit the
data from Tech2 to PC in the following procedure.
1. Startup TIS 2000.
2. Choose the “Snapshot Upload/Display” on the
initial screen of TIS 2000.
3. Either select the “Upload from diagnostic tool” or
click the appropriate icon on the tool bar.
4. Select the “Tech2” and transmit the saved
snapshot data.
5. Select the “Transmitted Snapshot”.
12. If the installation is completed, the “TIS 2000” icon
6. When the snapshot data transmission is
is displayed on the desktop.
completed, the data parameter list will appear on
* An error message may appear when restarting the screen.
the PC at Step 12.
In this case, install the following file in the CD-
ROM.
~cosids¥Diag¥Mdac_type.ex_
Copy this file on your hard disk, change the file
name into “mdac.exe”, and double-click
“mdac.exe”.
After this work, install TIS 2000 again.

How to display snapshot

Fig. 2: Data display (sample)

Fig. 1: “Application Selection” screen

 Electronic control fuel injection system (Common rail type) 1E-71
C. Display snapshot data with the “Snapshot
Upload” function of TIS 2000.
Snapshot data are stored in the PC hard disk or floppy
disk, and they can be displayed any time. Stored
snapshot can be displayed in the following procedure.
1. Startup TIS 2000.
2. Choose the “Snapshot Upload/Display” on the
initial screen of TIS 2000.
3. Either select the “Open file” or click the relevant
icon on the tool bar.
4. Select the “Transmitted Snapshot”.
5. When the snapshot data opens, the data
parameter list will appear on the screen.

Icons to be displayed
The following icons are used for data display.

Transmits the snapshot from Tech to PC.

Uploads the snapshot data from the floppy disk or hard disk.

Saves the snapshot data on the floppy disk or hard disk.

Displays the data parameters in one frame.

Displays the data parameters in two frames.

Changes the unit.

Displays the data parameters in graph and list (up to 3 parameter items for graph display).

Selects/cancels the parameter.

1E-72 Electronic control fuel injection system (Common rail type)

Displays the data parameters in graph only (up to 6 parameter items).

Prints (data parameter print out).

Snapshot data replay

Snapshot data can be replayed using icons in the bottom of the screen.

1st record: Displays the first record of the snapshot.

Previous record: Displays the previous record of that currently displayed.

Regeneration in reverse direction: Replays in the reverse direction.

Trigger of record: Moves to the trigger position and displays the snapshot.

Regeneration in forward direction: Replays all the snapshot in the forward direction.

Next record: Displays the next record of that currently displayed.

Last record: Displays the last record of the snapshot.

End of regeneration: Clicking the snapshot ends the replay of record.

 Electronic control fuel injection system (Common rail type) 1E-73
Graph display 6. Graph display can be moved with the navigation
Numeric value and graph (up to 3 for graph display): icons.
1. Clicking the icon for graph display opens “Graph 7. If you wish to view the graph with different
Parameters” window. parameter, drag the parameter in the list onto the
display screen. (Click the parameter and move the
2. Click the 1st graph icon in the top of the window,
cursor with the mouse button pressed, and then
and select one parameter from the list in the
release the mouse button in the display screen.)
bottom of the window. Selected parameter is
New parameter appears to replace the old one. To
shown next to the graph icon. Graph category can
view the graph in full screen, move the cursor to
be selected with the field located in the right hand
the top of the screen, and click the screen where
of the parameter.
the cursor changes to magnifying glass icon. This
3. Perform the same procedure for the 2nd and 3rd will display the graph in full screen.
graph icons.
4. After selecting all the parameters (up to 3 Graph display in one frame (up to 6 for graph
parameters) you wish to view, click the [OK] button. display)
1. Click the “Six graph” icon. This opens “Graph
Parameters” window.

Fig. 4: “Graph Parameters” window (sample)

5. Selected parameter is shown in graph form, in the Fig. 6: “Graph Parameters” window
right hand of the data parameter on the screen.
2. Click the graph icon, and select the parameter you
wish to view from the list. Change the graph
category as required.
3. Perform the same procedure for the 2nd to 6th
parameters with graph icons.
4. Clicking the [OK] button displays the graph.

Fig. 5: Graph display screen (sample)

1E-74 Electronic control fuel injection system (Common rail type)
5. In this case, parameters are available only in graph
form. All the parameters are shown in one frame.

Fig. 8: Parameter selection

Fig. 7: Graph display screen (sample) Directory to save data

Normally data is saved in “C:¥Program
6. Graph display screen can be moved with the Files¥cosids¥DATA¥SNAPSHOT¥” folder. This
navigation icons. directory is different if you changed installation directory
when installing the application. Two sample files
Selects/cancels the parameter. (“10000000SUR”, “10000001.SUR”) are already stored
when installing the application.
Use of parameter select/cancel function allows to select
particular parameter from the list and to display it
instantly. First click the parameter you want to view to
mark it, then click “Select/Cancel Parameters”.
Selected parameter is shown in the upper area of [Lock
line] on the top of the data list. Other parameters can be
added in the same procedure. Use of parameter
[LOCK] allows the parameters to be displayed
continuously for data comparison. To eliminate a
parameter from the list, click the parameter you want to
eliminate to put mark on it, then click “Select/Cancel
Parameters”. When quitting the [Snapshot Display]
application, “Do you want to save this file?” dialog box
appears automatically. The file can be saved on the PC
hard disk or floppy disk.
 Electronic control fuel injection system (Common rail type) 1E-75
TIS 2000 navigation
TIS 2000 application can be operated using the following icons.

[TIS2000 end]: Quits all TIS 2000 applications to return to the Windows desktop screen.

[Select page]: Returns to the initial page of TIS 2000 without quitting applications currently
used. The applications currently used run in the background.

[Vehicle data]: Starts [Vehicle data display] function. This displays all the vehicle information.

[Executed applications end]: Quits the application currently used to return to the initial page of
TIS 2000.

[Session]: Allows to register and display user information.

[Print]: Prints the screen.

[Help]: Launches the integrated help function of TIS 2000.

Software download

Herein, it is described about how to update Tech2

software using “Software Download” function of TIS
2000.

Updating Tech2 (Software download)

Update the Tech2 software to the latest version using
“Software Download” function of TIS 2000.
Tech2 software is updated on a regular basis to
correspond to the change in vehicle specifications and
diagnostic methods. Updated information includes new
vehicle system, amendment of diagnostic method,
update from previous version, addition of new
diagnostic method, etc.

There are two kinds of download mode; “Standard” and

“Custom”.

Fig. 1: “Application Selection” screen

1E-76 Electronic control fuel injection system (Common rail type)
Standard update (This mode is not used this time. 8. When the transmission is completed,
Select the “Custom”.) “Transmission is completed” will appear on the
Description: Standard mode can be used only when the screen. Click the “Close” button to quit the
old version of software is installed and registered in the application. The latest software has been
database. Only “Custom” mode can be used in any transmitted to the diagnostic tool.
other cases. In “Standard” mode, the latest version will
be installed for the language and the model Custom update
(manufacturer) which are set in Tech2 at that time. Use custom update when installing the old version
software, software other than Isuzu software or
The procedure of Tech2 “Standard” update, using software with different language, or when the database
“Software Download” function, is as follows. cannot identify the software version being installed.
1. Connect the Tech2 to the PC with RS-232C cable. After selecting “Custom” on the selection screen (See
2. Connect the standard accessory power cable to Fig. 2), perform the following procedure.
Tech2.
3. Startup TIS 2000 on the PC. 1. The “Application Selection” appears on the screen.
4. Choose “Software Download” icon on the initial The list of the software release No. appears on the
screen of TIS 2000. left hand of the screen. Clicking [+] mark allows to
5. Check the selected location on the “Select view the list of available language of each release.
Diagnostic Tool for Download” screen, and go to
next.

Fig. 3: Selection of application for “Custom” mode

Fig. 2: Selection of diagnostic tool to be updated and 2. Either double-click the relevant software version
update mode and language, or click the “Select” button to select.
The software you have chosen appears on the
• Check the selected location and click “Next”. An right hand of the screen. To compare current
explanation appears as “Reading information of software with selected software of the diagnostic
diagnostic tool”. tool, click the mark on the right hand of the screen.
3. Clicking the [Download] button starts updating.
6. The “Software Update Confirmation” screen 4. “Transmitting Software” appears on the screen to
appears on the PC. tell the transmission status.
Also, the stored contents of the current Tech2 and 5. When the transmission completes, “Transmission
stored data after transmitting diagnostic software is completed” will appear on the screen. Click the
appear on the screen. Click the [Continue] to go “Close” button to quit the application. The selected
on. software has been transmitted to the diagnostic
7. “Transmitting Software” appears on the screen to tool.
tell the transmission status.
 Electronic control fuel injection system (Common rail type) 1E-77
TIS 2000 navigation
TIS 2000 application can be operated using the following icons.

[TIS2000 end]: Quits all TIS 2000 applications to return to the Windows desktop screen.

[Select page]: Returns to the initial page of TIS 2000 without quitting applications currently
used. The applications currently used run in the background.

[Vehicle data]: Starts [Vehicle data display] function. This displays all the vehicle information.

[Executed applications end]: Quits the application currently used to return to the initial page of
TIS 2000.

[Session]: Allows to register and display user information.

[Print]: Prints the screen.

[Help]: Launches the integrated help function of TIS 2000.

Snapshot transmission method using e-mail

• Upload the snapshot data from Tech2 to hard disk
on PC.
• Open the file in the following procedure to
download data.
• Double-click “C: ¥Program Files”.
• Double-click the “cosids” folder.
• Double-click the “DATA” folder.
• Double-click the “SNAPSHOT” folder to download.
• Make sure that the file extension is “.sur”, and
attach the file to e-mail.
1E-78 Electronic control fuel injection system (Common rail type)

How to Inspect Injector

How to use injector checker

Components of injector checker

TSWG0211

Name
1. Injector checker body 3. Test harness for 4-cylinders
2. Test harness for 6-cylinders

* To prevent wrong connection, the end of corrugate tube of connection harness for 6-cylinders is wrapped by
identification tape (red) for 4-5-6 cylinder side harness.
 Electronic control fuel injection system (Common rail type) 1E-79
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 cylinder
4 selection switch. Injection of selected cylinder stops
approx. 2.4 seconds.

Operation lamp
This comes on while injector is checked (approx. 2.4
3 5 seconds) after starting button is pressed.

Note:
2 Do not use any switches and operate the machine
while the lamp comes on. Otherwise, diagnosis
result is not correct.

1 Holder
TSWG0212 Holders are used to hang or fix the body. They are
tightened on the body. To use the holders, loosen the
Name screws to move.
1. Main switch
2. Battery lamp Note:
3. Operation lamp • When using or storing holders, be sure to
4. Cylinder selection switch tighten them to fix.
5. Start button • Be careful not to tighten screws excessively.
This 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
harness.

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 Battery Replacement)

Note:
When using the main switch, it comes on
momentarily due to voltage change. If the battery
lamp does not come on when using the main TSWG0221
switch, check the battery. Replace it if it gets low
(7.2V or less). Precautions on handling the body
• The body is a precision equipment. Do not drop
Cylinder selection switch 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 internal battery, not from external one.
to check twice for each cylinder. At the third
• Prevent foreign matter from entering into the
time or later, turn the selection switch left back
body while replacing battery.
to the original position and start to check.
1E-80 Electronic control fuel injection system (Common rail type)
• Do not use screws to tighten battery holder 4. Connect the test harness to the engine side.
except original ones. This may cause body
damage or battery damage and electric Note:
leakage. • Be careful not to let the metal parts of test
• Do not disassemble the body in any harness and connector contact glow plug
circumstances. Contact the machine connector. Protect it with cloth to prevent short
manufacturer or ISUZU Industrial Engine during operation of key switch.
Service Dept. if it is faulty. • Do not connect wrong connector. (Confirm the
identification tape (red) before connecting.)
Injector test • DTC will be detected if disconnecting or
1. Check the DTC. connecting the harness with the key switch to
• If DTC unrelated to injector is detected, repair or ON. Turn it to OFF during work.
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

* 4HK1 is shown in the illustration.

Note:
Be careful not to let the metal parts of connector
contact glow plug connector while connecting the
TSWG0213
harness.
6HK1

#4,5,6
#1,2,3

TSWG0216
TSWG0223
 Electronic control fuel injection system (Common rail type) 1E-81
5. Connect the test harness to the body. 15. Perform a test drive, and check that there are no
• Do not directly place the body on the engine. faults.
• Avoid high vibration and impact.
Battery Replacement
1. Remove the two screws on the side of the body.

TSWG0214

6. Start the engine. TSWG0217

7. If the machine has function to lower idle speed,
lower the speed to clarify the engine reaction. 2. Pull out the battery holder.
8. Set the selection switch to “1”, and check the No. 1
cylinder.
9. Press the start button and check the engine
vibration level and change in exhaust noise.
• If it is difficult to recognize the change, touch the
engine directly to check change in the vibration.

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:
For work procedure, refer to “Engine section” in
the service manual. TSWG0218

12. Turn the key switch to OFF, remove the test

harness, 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 during work.

13. Start the engine and return the idle speed at

specified one.
14. Clear the DTC.
Refer to the machine’s manual for how to clear
DTCs.
1E-82 Electronic control fuel injection system (Common rail type)
3. Remove the battery from the holder. 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 each machine
manufacturer at the end of this manual.

Method to identify
1. Method of judgment by an injector balance test
using a diagnostic tool with KW or CAN
communication such as Tech2.
• For the procedure of a balance test, refer to the
“Injector balance test” in “How to use scan tool”.
2. Method of judgment by such an injector balance
test that the injector power line is broken for a short
time using an injector checker without
communication with the ECM.
TSWG0219
• Refer to “How to use injector checker”.
4. Disconnect the connector from battery, and replace 3. Method of judgment by measuring and comparing
the battery. 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
comparing 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.
Measuring period should be 3 to 5 minutes after the
engine stabilized. Measure and compare the exhaust
pipe temperature of each cylinder, and judge as faulty
cylinder if the temperature of certain cylinder is
TSWG0220 significantly lower than others.
5. Restore in the reverse order.
Comparing exhaust pipe temperature of engine unit
Note: alone
• Prevent foreign matter from entering in while
Note:
removing the battery.
Reference for test on engine unit. Test results will
• Do not tighten the battery holder screws show similar tendency when trouble occurs
excessively. although variation may differ depending on
• Do not replace the battery holder screws with machine type and measuring conditions.
other than original ones.
• Be sure to use specified battery. Note:
Be careful not to continue the test condition for a
long time. Otherwise the test result may be
incorrect due to heat conduction of the exhaust
pipe.
 Electronic control fuel injection system (Common rail type) 1E-83
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 or than normal cylinders.
No. 6 cylinder stops
Refer to the relevant section for the reference value of
each machine manufacturer.
500
(932)

400
(752)

300
(572)
C ( F)

200
(392)

100
(212) #1/#6

0
(32)
TSHK0136

When injection in No. 1 or No. 6 cylinder stops, there

are significant difference in the temperature between
No. 1 or No. 6 cylinder and other cylinders that perform
normal injection.
1E-84 Electronic control fuel injection system (Common rail type)

How to use flash tool

Introduction

Only the person with approval of the machine manufacturer or engine manufacturer
can reflash ECM using EMPS.
 Electronic control fuel injection system (Common rail type) 1E-85

Cautions

For your safety, read the following cautions.

1. Always turn the POWER switch of EMPS selector 6. Avoid using and storing it in a place that it may
to OFF before connecting/disconnecting the cables. contact water or chemicals. When cleaning, use
Before turning on the POWER switch of EMPS cloth with mild detergent, not highly-volatile solvent
selector, make sure that the cables are connected such as thinner, and wipe out using dry cloth.
securely.

DATA ECM
SELECT POWER
POWER READY READ ON

WRITE OFF

RS-232C ECM FUSE POWER

POWER
OWER ON
O

7. Avoid using and storing it in dusty area. Store it to

2. Do not disassemble the EMPS selector. avoid dust on the connector etc. when you don’t use.
3. ECM can be reflashed up to around 100 times. (The
number of times varies depending on the conditions
of use.䋩
4. If the POWER lamp does not come on when turning
the POWER switch ON with the power source
connected, check the fuse.
5. Do not have an impact on it by dropping. It causes
internal faults even no damage on appearance.
1E-86 Electronic control fuel injection system (Common rail type)

8. Avoid using and storing it in a place with rapid

changes of temperature. If bringing it from cold
outside into warm indoor suddenly, dew
condensation may occur resulting in malfunction or
trouble.

9. Avoid using and storing it in a place with extreme

high or low temperature. Especially in summer, do
not leave it in the machine exposed to direct
sunlight.
 Electronic control fuel injection system (Common rail type) 1E-87

EMPS Component Parts

11

5 4 3 2 1

6 7 8 9 10

TSWG0222

Names
1. Selector
2. ECM POWER switch
3. DATA SELECT switch
4. READY lamp
5. POWER lamp
6. RS-232C connector
7. ECM connector
8. Fuse
9. POWER switch
10. ECM connection cable
11. Battery cable

(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).
1E-88 Electronic control fuel injection system (Common rail type)

ECM (Hardware) Compatibility

Ɣ ECM (hardware) that can be reflashed has no compatibility.

Use the ECM that corresponds to the engine type and voltage specification.
Voltage Specifications
㪈㪉㪭㩷㪪㫇㪼㪺 㪉㪋㪭㩷㪪㫇㪼㪺
㪋㪟㪢㪈 㪋㪟㪢㪈
㪜㫅㪾㫀㫅㪼 㪍㪟㪢㪈 㪍㪟㪢㪈
㪫㫐㫇㪼 㪍㪮㪞㪈 㪍㪮㪞㪈 ECM (hardware) for 6WG1 and 6U is the same.
㪍㪬 㪍㪬
㪋㪡 㪋㪡

Ɣ Using EMPS can reflash the ECM of industrial common rail engine only.
Ɣ Using EMPS cannot reflash the ECM of industrial engine (RED-4 type injection system) that meets Phase 2
Emission Standards.

System Requirements for EMPS Software (Recommended)

System Component Specifications

PC PC/AT compatible machine
CPU Pentium III 800 MHz or more
OS Windows 2000 SP4, Windows XP SP1, SP2 in Japanese or English
version
Memory 256MB or more
HDD 20GB or more

Video card 1024 x 768 dots or more, 256-color or more

Serial interface One or more RS232C ports (USB conversion connector etc. is also
available)

External drive CD-ROM drive

 Electronic control fuel injection system (Common rail type) 1E-89

EMPS (Software) Setup Procedure

(1) Insert the “EMPS setup CD” into the CD-ROM drive.
This automatically starts up the setup program, and the following message appears.

Quit other application if it is running. Click the [OK] button.

To cancel installation, click the [Cancel] button.

Read the license agreement. If you agree to the terms, click [Agree to the terms of this agreement] and click the [OK]
button.
If you do not agree, click [Disagree to the terms of this agreement] and click the [OK] button to end the setup.
1E-90 Electronic control fuel injection system (Common rail type)

(2) Enter the user name and password, and then click the [Next] button.

(3) Configure operating environment.

Configure the work folder that system uses, the initial value of the COM port, and the initial value of the data
transmission rate, and click the [Complete] button.
COM port and data transmission rate can be changed later. If you are not sure about this setting, do not change the
value and click the [Complete] button.

(4) After the user name and password are verified, the following display appears.
Click the [Next] button.
 Electronic control fuel injection system (Common rail type) 1E-91

(5) In the following display, confirm the installation destination and click the [Next] button.
To change the installation destination, click the [Browse] button and select the folder you want to install.

(6) This starts the setup, and the following display appears.
To cancel the setup halfway, click the [Cancel] button.

(7) Setup completion

The setup is completed, and the following display appears. Select [Yes, restart the computer now], and then click the
[Finish] button.
*You can also select [No, I will restart the computer later], but unexpected error may occur if you reflash with the
EMPS before restart. Be sure to restart the computer before starting the EMPS.
1E-92 Electronic control fuel injection system (Common rail type)

System version upgrade:

If the system has been upgraded, the update program will start automatically after the CD is inserted.
The following message will appear. Quit the EMPS if it is running, and click the [OK] button.
Clicking the [Cancel] button cancels the update process. Update must be performed before reflash with EMPS.
 Electronic control fuel injection system (Common rail type) 1E-93

EMPS Operation Procedure

1. Preparation
2. EMPS Selector Connection
3. Startup
4. User Authentication Screens
4.1 User Authentication Screen (Normal)
4.2 User Authentication Screen (Compulsory Reflash)
4.3 OEM Manufacturer Selection Screen
5. Connection Confirmation Screen
5.1 PC Setting
6. Switch Confirmation Screen (1)
7. Main Menu
7.1 External Power Confirmation Screen
7.2 Voltage Confirmation Screen
8. Selected Item Confirmation Screen
9. Switch Confirmation Screen (2)
10. Former ECM Parts Number Confirmation Screen
11. New ECM Parts Number Search Screen
12. New ECM Parts Number Search Confirmation Screen
13. Replacement ECM Parts Number Confirmation Screen
14. Switch Confirmation Screen (3)
15. Switch Confirmation Screen (4)
16. READY LED Confirmation Screen (1)
17. Switch Confirmation Screen (5)
18. Reflashing Execution Confirmation Screen
19. Switch Confirmation Screen (6)
20. Switch Confirmation Screen (7)
21. READY LED Confirmation Screen (2)
22. Switch Confirmation Screen (8)
23. Reflashing Result Confirmation Screen
24. Switch Confirmation Screen (9)
25. Cable Removal Confirmation Screen
26. Final Result Confirmation Screen
27. Memory Clear
28. Recover Point
29. Error Messages
30. Error Code List
1E-94 Electronic control fuel injection system (Common rail type)

1. Preparation
1. Printed label with update parts number is necessary to proceed reflashing in all countries except the US. Proceed
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.
After reflashing, you need to write down the new Parts Number on a label and attach it on the ECM.
2. Check the serial number of the selector, and have your user ID and password ready.
3. Check the engine serial number.
4. To perform compulsory reflash, obtain the specific password from the machine manufacturer or the engine
manufacturer.

2. EMPS Selector Connection

Using power supply

Using battery
 Electronic control fuel injection system (Common rail type) 1E-95

Connection Procedure: Removal Procedure:

1. Turn the POWER SW (1) to OFF. 1. Turn the POWER SW (1) to OFF.
2. Connect the RS-232C cable (2). 2. Remove the AC adapter or battery cable (4).
3. Connect the ECM harness (3). 3. Remove the ECM harness (3).
*Do not roll up the harness cord. 4. Remove the RS-232C cable (2).
4. Connect the AC adapter or battery cable (4). 5. Eject the Data CD (5) from the PC.
5. Insert the Data CD (5) into the PC.

(Caution)
٨ When drawing power from a battery : <Do not use an AC adapter at the same time.>
٨ When drawing power with the AC adapter : <Use the optionally available adapter.>
Use a DC plug (model number: MP-121C; outer diameter: 5.5 mm
˜ inner diameter: 2.1 mm, DC 12 V – 0.5 A).
: <Prepare an AC adapter that matches the rating (12V/24V) of
the ECM.>
: <Do not use an AC adapter at the same time with a battery.>
٨ Do not roll up the ECM harness. Data communication error will result.
٨ Make sure that the POWER switch of EMPS selector is turned to OFF before connecting/disconnecting the
ECM harness. Damage to EMPS or ECM selector will result.
1E-96 Electronic control fuel injection system (Common rail type)

3. Startup

Double-click the EMPS icon on your Windows desktop to display the initial startup screen.

Clicking the [Next] button displays the message shown below.

Clicking the [OK] button displays the connection procedure screen shown below.
 Electronic control fuel injection system (Common rail type) 1E-97

Connect the PC, selector, and ECM according to the procedure.

After connection, click the [Next] button to proceed to the mode selection screen.

㩷 㩷 㩷 㩷 Normal:
Compatible parts number with reflashed parts
number is searched automatically and updated.

㩷 㩷 㩷 㩷 㩷 Compulsory reflash:
An arbitrary parts number is designated and
updated. Select this when reflashing was failed,
or when reflashing the parts number with no
compatibility.
Specific password is necessary.

㩷 㩷 㩷 㩷 㩷 Campaign:
This is performed at the campaign designated
by manufacturer. After reflashing, send the
campaign log file created to the administrator.

Select [Normal Update], [Enforce Update] (compulsory reflash), or [Campaign Update], and then click the [Next] button.

One of the following operations is performed when the [Next] button is clicked.
Selected Option Settings/Operation Performed
Normal Update Advances to "4.1 User Authentication Screen (Normal)."
Enforce Update Advances to "4.2 User Authentication Screen (Compulsory
Reflash)."
Campaign Update Advances to "4.1 User Authentication Screen (Normal)."

Clicking the [Next] button displays the message shown below.

Check the content, and click the [OK] button to advance to next.
1E-98 Electronic control fuel injection system (Common rail type)

4. User Authentication Screens

These screens are used for EMPS user authentication.

4.1 User Authentication Screen (Normal)

After entering information in the ID and PASSWORD boxes, click [Next] to advance to "4.3 OEM Manufacturer
Selection Screen."
To cancel user authentication at any point, click the [Cancel] button.

4.2 User Authentication Screen (Compulsory Reflash)

After entering information in the ID, PASSWORD, and Enforce Update PASSWORD (Password for compulsory
reflash) boxes, click [Next] to advance to "4.3 OEM Manufacturer Selection Screen."
To cancel user authentication at any point, click the [Cancel] button.

4.3 OEM Manufacturer Selection Screen

After selecting the OEM manufacturer, click [OK] to advance to "5. Connection Confirmation Screen."
 Electronic control fuel injection system (Common rail type) 1E-99

5. Connection Confirmation Screen

This screen shows the connection status of the computer, selector, ECM, and power supply/battery.

After selecting the COM port (Communication port) and transmission bit rate (Bit/sec), click [Next] to advance to "6.
Switch Confirmation Screen (1)."

Selection Item Descriptions

Item Description
COM port Select the RS232C port to which the selector is connected.
Transmission bit Select the data transmission bit rate.
rate
Cancel button Displays a confirmation message for exiting the tool.

Next button Performs a check and then displays "6. Switch Confirmation Screen (1)."

One of the error messages will appear if an error is discovered by the check that is performed when the [Next] button is
clicked. Go to "29. Error Messages."
1E-100 Electronic control fuel injection system (Common rail type)

5.1 PC Setting
Normally select COM1 if RS232-C is used for connection.
In the case of a PC that is not equipped with an RS232-C port, connect using a commercially available USB conversion
cable. For details about port settings, refer to the user documentation that comes with the USB conversion cable.

<To check standard COM port settings>

1. On the Windows [Start] menu, select [Control Panel].
2. On [Control Panel], open [System].
3. When system properties appear, select [Hardware].

Windows XP Windows 2000

㩷

4. Select [Device Manager] to open it.

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

Windows XP Windows 2000

6. In the displayed items for communication ports, confirm the COM port to which the EMPS is connected.
 Electronic control fuel injection system (Common rail type) 1E-101

6. 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.

Turn on the power switch, and then click the [Next] button.

This starts selector confirmation, and displays the message shown below.

If response from the selector is normal, advance to "7. Main Menu" screen.
One of the following messages will appear if any abnormality is discovered. Click [Return to User Authentication
screen], and check the user ID. To continue the process as is, click [Continue process].

If a communication error occurs, advance to the "28. Recover Point" screen.

1E-102 Electronic control fuel injection system (Common rail type)

7. Main Menu
This is the EMPS main menu.
After configuring Select Tool, Select ECM Location, and Select Program Process, click the [Next] button.

Selection Item Descriptions

Item Settings/Operation Performed
Select Tool Engine
Module
Programming System (EMPS)
Select ECM Location On the machine
Off the machine
Select Program Process Service ECM
Production ECM
Back button Returns to "5. Connection Confirmation Screen."
Next button When "On the machine" is selected, advances to "7.1 External Power
Confirmation Screen."
When "Off the machine" is selected, advances to "7.2 Voltage Confirmation
Screen."

7.1 External Power Confirmation Screen

This screen prompts for confirmation of an external power supply.

Clicking the [Yes] button on the external power confirmation screen advances to "8. Selected Item Confirmation
Screen."
If an external power supply cannot be connected, click the [No] button to return to "7. Main Menu."
Clicking the [Help] button will display the message shown below.
 Electronic control fuel injection system (Common rail type) 1E-103

7.2 Voltage Confirmation Screen

This screen prompts for confirmation of proper voltage.

Clicking the [Yes] button on the voltage confirmation screen advances to "8. Selected Item Confirmation Screen."
If battery voltage cannot be confirmed, click the [No] button to return to "7. Main Menu."
Clicking the [Help] button will display the message shown below.

8. Selected Item Confirmation Screen

This screen shows the details of the settings configured up to this point.
If there is no problem with the displayed settings, click [Next] to advance to "9. Switch Confirmation Screen (2)."
To change the settings, click [Back] to return to "7. Main Menu."
1E-104 Electronic control fuel injection system (Common rail type)

9. Switch Confirmation Screen (2)

The switch confirmation screen is shown below.

Configure the switch settings as shown below.

DATA SELECT Switch : READ

ECM POWER Switch : ON

After configuring the switch settings, click the [Next]

button.

This starts selector confirmation, and displays the message shown below.

If response from the selector is normal, advance to "10. Former ECM Parts Number Confirmation Screen."
One of the messages will appear if any abnormality is discovered. Go to "29. Error Messages."
If a communication error occurs, advance to the "28. Recover Point" screen.

10. Former ECM Parts Number Confirmation Screen

This screen displays the former parts number.
Clicking the [Next] button advances to "11. New ECM Parts Number Search Screen."
To cancel former ECM parts number confirmation, click the [Cancel] button.
 Electronic control fuel injection system (Common rail type) 1E-105

11. New ECM Parts Number Search Screen

This screen displays the new parts number.
Select the ENGINE MODEL and ENGINE TYPE, and then click the [Select] button.
Next, select the OEM NAME, input the ENGINE NUMBER, and then click the [Next] button.
To return to "10. Former ECM Parts Number Confirmation Screen," click the [Back] button.

Selection Item Descriptions

Item Settings/Operation Performed
ENGINE MODEL Select the engine model that corresponds to the former parts number.
In the case of enforced update, you can select all engine models.
ENGINE TYPE Select the engine type that corresponds to the former parts number.
In the case of enforced update, you can select all engine types.
Select button Extracts the applicable OEM names for the applicable ENGINE MODEL
and ENGINE TYPE, and provides them for selection in the OEM NAME
box.
OEM NAME Select the OEM NAME from among those that correspond to the selected
ENGINE MODEL and ENGINE TYPE.
ENGINE NUMBER Enter an arbitrary engine number in 6 digits. If the number is less than 6
digits, the following message will appear.

Back button Returns to "10. Former ECM Parts Number Confirmation Screen."
Next button Performs a check and then advances to "12. New ECM Parts Number
Search Confirmation Screen."

A message will appear if an error is discovered by the check that is performed when the [Next] button is clicked.
Go to "29. Error Messages."
1E-106 Electronic control fuel injection system (Common rail type)

12. New ECM Parts Number Search Confirmation Screen

This screen displays the search results.
After checking the contents, click the [Next] button to advance to "13. Replacement ECM Parts Number Confirmation
Screen."
If the search results do not show the parts number you want, select the [To enter other interchangeable part number,
select the "NEW ECM PARTS NUMBER INPUT" check box and enter it into the field below.], and then input the
correct parts number. (Be sure you input an interchangeable parts number.)
To return to "11. New ECM Parts Number Search Screen," click the [Back] button.

XYSZ-01
AIMI
 Electronic control fuel injection system (Common rail type) 1E-107

13. Replacement ECM Parts Number Confirmation Screen

This screen shows the replacement ECM parts number.
After checking the contents, click the [Next] button to perform a CD check and advance to "14. Switch Confirmation
Screen (3)."
To return to "11. New ECM Parts Number Search Screen," click the [Back] button.

The following message will appear during the CD check if a CD is not inserted or if the version does not match.
Click the [OK] button to exit the program.

If program file name acquisition fails, advance to "28. Recover Point."

1E-108 Electronic control fuel injection system (Common rail type)

14. Switch Confirmation Screen (3)

The switch confirmation screen is shown below.

Configure the switch settings as shown below.

DATA SELECT Switch : READ

ECM POWER Switch : OFF

After configuring the switch settings, click the [Next]

button.

This will start data confirmation, display the message shown below, and advance to "15. Switch Confirmation Screen
(4)."

15. Switch Confirmation Screen (4)

The switch confirmation screen is shown below.

Configure the switch settings as shown below.

DATA SELECT Switch : WRITE

ECM POWER Switch : OFF

After configuring the switch settings, click the [Next]

button.
This will advance to "16. READY LED Confirmation
Screen (1)."
 Electronic control fuel injection system (Common rail type) 1E-109

16. READY LED Confirmation Screen (1)

The selector LED confirmation screen is shown below.
After confirming that the LED is lit, click [Yes] to advance to "17. Switch Confirmation Screen (5)."
If confirmation is not possible, click the [No] button to return to "13. Replacement ECM Parts Number Confirmation
Screen."

17. Switch Confirmation Screen (5)

The switch confirmation screen is shown below.

Configure the switch settings as shown below.

DATA SELECT Switch : WRITE

ECM POWER Switch : ON

After configuring the switch settings, click the [Next]

button.

This will start data confirmation, display the message shown below, and advance to "18. Reflashing Execution
Confirmation Screen."
1E-110 Electronic control fuel injection system (Common rail type)

18. Reflashing Execution Confirmation Screen

This screen displays a confirmation message for reflashing.
Click the [OK] button to continue.
If you need to make changes, click the [Cancel] button to return to "10. Former ECM Parts Number Confirmation
Screen."

This starts reflashing and displays the message shown below.

After reflashing is complete, advance to "19. Switch Confirmation Screen (6)."

One of the messages shown below will appear if an error occurs during reflashing. (Refer to [30. Error Code List].)

Click the [Yes] button to return to "18. Reflashing Execution Confirmation Screen."
Click [No] to advance to "28. Recover Point."
 Electronic control fuel injection system (Common rail type) 1E-111

19. Switch Confirmation Screen (6)

The switch confirmation screen is shown below.

Configure the switch settings as shown below.

DATA SELECT Switch : WRITE

ECM POWER Switch : OFF

After configuring the switch settings, click the [Next]

button.

This will start data confirmation, display the message shown below, and advance to "20. Switch Confirmation Screen
(7)."

20. Switch Confirmation Screen (7)

The switch confirmation screen is shown below.

Configure the switch settings as shown below.

DATA SELECT Switch : READ

ECM POWER Switch : OFF

After configuring the switch settings, click the [Next]

button.

This will start communication with the selectors and advance to "21. READY LED Confirmation Screen (2)."

A message will appear if an error occurs during communication. Go to "29. Error Messages."
If a communication error occurs, advance to the "28. Recover Point" screen.
1E-112 Electronic control fuel injection system (Common rail type)

21. READY LED Confirmation Screen (2)

The selector LED confirmation screen is shown below.
After confirming that the LED is unlit, click [Yes] button to advance to "22. Switch Confirmation Screen (8)."
If confirmation is not possible, click the [No] button to return to "20. Switch Confirmation Screen (7)."

22. Switch Confirmation Screen (8)

The switch confirmation screen is shown below.

Configure the switch settings as shown below.

DATA SELECT Switch : READ

ECM POWER Switch : ON

After configuring the switch settings, click the [Next]

button.

This starts data confirmation. After confirmation is complete, advance to "23. Reflashing Result Confirmation Screen."

A message will appear if an error occurs during confirmation. Go to "29. Error Messages."
If a communication error occurs, advance to the "28. Recover Point" screen.
 Electronic control fuel injection system (Common rail type) 1E-113

23. Reflashing Result Confirmation Screen

This screen displays the parts number reflash result.

Clicking the [Next] button displays the message shown below.

Check the content and click the [OK] button to advance to "24. Switch Confirmation Screen (9)."
1E-114 Electronic control fuel injection system (Common rail type)

24. Switch Confirmation Screen (9)

The switch confirmation screen is shown below.

Configure the switch settings as shown below.

DATA SELECT Switch : READ

ECM POWER Switch : OFF

After configuring the switch settings, click the [Next]

button.

After turning the power switch to OFF, click the [Next]

button to advance to "25. Cable Removal Confirmation
Screen."
 Electronic control fuel injection system (Common rail type) 1E-115

25. Cable Removal Confirmation Screen

Disconnect the cable which connects the selector to ECM, and then click the [Next] button.
Advance to "26. Final Result Confirmation Screen."

26. Final Result Confirmation Screen

This screen displays the result of the reflashing.
Click the [OK] button to advance to "27. Memory Clear."

XYSZ-01
AIMI
1E-116 Electronic control fuel injection system (Common rail type)

27. Memory Clear

Perform memory clear in accordance with the instructions that are displayed.

Clicking the [OK] button displays the procedure shown below.

After memory clear is complete, click the [Clearing memory is completed.] button to exit the program.
 Electronic control fuel injection system (Common rail type) 1E-117

28. Recover Point

When data exchange with the selector is not performed correctly, you can select the point from which to continue the
procedure.

The procedure that can be continued depends on where the communication error was generated.
Item Description
Continue the procedure from Connection Confirmation Returns to "5. Connection
screen. Confirmation Screen."
Continue the procedure from Main Menu screen. After the Switch Confirmation Screen
is displayed, returns to "7. Main Menu
Screen."
Continue the procedure from Current ECM Parts Number After the Switch Confirmation Screen is
Confirmation screen. displayed, returns to "10. Former ECM
Parts Number Confirmation Screen."
Continue the procedure from confirmation process after After the Switch Confirmation Screen is
reflashing. displayed, returns to "20. Switch
Confirmation Screen (7)."

To continue, select a process and then click [Continue].

For some processes, a switch confirmation screen will appear. Configure switch settings as instructed, and then
click the [Next] button.

Switch Confirmation screen for "Continue the procedure from Main Menu screen."
1E-118 Electronic control fuel injection system (Common rail type)

Switch Confirmation screen for "Continue the procedure from Current ECM Parts Number Confirmation screen."

Switch Confirmation screen for "Continue the procedure from confirmation process after reflashing."

To exit the program without continuing, click the [Cancel] button. After the message shown below appears, click the
[OK] button to exit the program.
 Electronic control fuel injection system (Common rail type) 1E-119

29. Error Messages

(1) 3. Startup Errors

Depending on the setup and operating environment, any one of the following error messages may appear during
startup.
Error Type Error Message Description Response
Operating The system is not Reinstall the system.
environment ready because
setting error operating
environment setting is
not correct.
(Refer to "30. Error
Code List".)

CD-ROM CD-ROM drive Check the CD-ROM drive.

error cannot be found.

No CD is inserted in Insert the Data CD into the

the CD-ROM drive. CD-ROM drive.

CD-ROM CD-ROM read error Check the CD-ROM drive

read error (Refer "30. Error and Data CD. Contact your
Code List".) administrator if there is no
fault.

Data read CD-ROM data read Check the CD-ROM drive

error error and Data CD. Contact your
(Refer to "30. Error administrator if there is no
Code List".) fault.
1E-120 Electronic control fuel injection system (Common rail type)

(2) 4. User Authentication Errors

One of the following error messages appear if the ID and/or password is not input, or if the input is incorrect.
Error Type Error Message Description Response
No input ID not input. Enter your ID.

Password not input. Enter your password.

Incorrect Password is wrong. Enter your correct password.

password

No input Password for Enter the password for

compulsory reflash not compulsory reflash.
input.

Incorrect Password for Enter the correct password for

password for compulsory reflash is compulsory reflash.
compulsory wrong.
reflashing

Password for Obtain the correct password

compulsory reflash for compulsory reflash from
has expired. your administrator.

OEM not OEM NAME not Select OEM NAME.

selected selected.

Database read Service address is not Check the Data CD. Contact
error found in the database. your administrator if there is
no fault.
 Electronic control fuel injection system (Common rail type) 1E-121

(3) 5. Connection Confirmation Errors

Error Type Error Message Description Response

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

COM port input value Enter the correct COM port.

is not correct.

COM port Check if COM port operates

communication error properly.

Last process Last process

check continuation
confirmation 䋭
Click the [Yes] button to
advance to "10. Former
ECM Parts Number
Confirmation Screen."
This message appears
to confirm deletion
when the [No] button 䋭
of the above message
box is clicked.
1E-122 Electronic control fuel injection system (Common rail type)

(4) 6. Switch Confirmation (1) Errors

One of the following messages will appear if any abnormality is discovered.

Error Type Error Message Description Response

Communicati Serial number Click the [OK] button to exit the
on with the transmission failure process, and then check the
selector selector.

Send error Click the [OK] button to exit the

process, and then check the
selector. If the error occurs
again, contact the administrator.

Response Response from the Click the [OK] button to exit

from selector selector is incorrect. the process, and then check
the selector.
 Electronic control fuel injection system (Common rail type) 1E-123

(5) 9. Switch Confirmation (2) Errors

One of the following messages will appear if any abnormality is discovered.

Error Type Error Message Description Response

Incorrect Check of current parts Click the [OK] button to
former parts number return to "7. Main Menu."
number Clicking the [Cancel] button
displays a message to confirm
exiting of the program.

Exit A confirmation Click the [OK] button to exit

confirmation message that tells the program.
system ends Click the [Cancel] button to
return to "7. Main Menu."

Communicati Parts Number Click the [OK] button to exit the

on with the transmission failure process, and then check the
selector selector.

Service Service address does Click the [Yes] button to

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

Parts Number Parts Number cannot Click the [Yes] button for
acquisition be obtained. integrated confirmation
process. To cancel the
process, click the [No] button.

Execution
confirmation of
integrated
confirmation process -
if clicking the [Yes] in
the massage above

Parts Number cannot Perform the compulsory

be obtained even after reflash. If this message
the integrated appears in the compulsory
confirmation process. reflash process, ECM may be
damaged.
1E-124 Electronic control fuel injection system (Common rail type)

(6) 11. New ECM Parts Number Search Screen Errors

Error Type Error Message Description Response

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

OEM NAME not Select the OEM NAME.

selected.

ENGINE NUMBER not Enter the ENGINE NUMBER.

input.

Search error Parts number search Click the [OK] button and follow
failed. the next screen.

Parts Number entered Confirm the Parts Number

for compulsoty and enter it again.
reflash is not found.

Parts number entered Confirm the Parts Number

is not compatible with and enter it again.
current Parts Number.

CD-ROM CD-ROM read error Check the CD-ROM.

CD-ROM cannot be Check the CD-ROM.

found.
 Electronic control fuel injection system (Common rail type) 1E-125

(7) 18. Reflashing Execution Confirmation Screen Errors

Error Type Error Message Description Response

Incorrect parts Command error Click the [OK] button to
number during reflashing advance to "28. Recover
Point."
To cancel, click the [No]
button.

This message appears Click the [OK] button to

when the [No] button return to "4. User
of the above message Authentication Screens."
box is clicked.

(8) Other common error

Error Type Error Message Description Response

Send error Communication error Click the [OK] button, switch the
at data transmission selector to continue or exit the
(Refer to "30. Error process.
Code List".)

Confirmation Switch status is Check the switch status of

of Switch incorrect. selector.

Campaign Campaign log file Check the HDD has enough

output error free space, and perform the
process again.

Campaign log file Check the HDD has enough

output error free space, and perform the
process again.

Campaign log file Check the HDD has enough

output error free space, and perform the
process again.
1E-126 Electronic control fuel injection system (Common rail type)

30. Error Code List

Type Code Message Description

Start-up
0001 Operating environment setting error Work folder acquisition
Reinstall the EMPS.
If the error occurs again, contact the administrator.

0002 Operating environment setting error Work folder does not exist.
Reinstall the EMPS.
If the error occurs again, contact the administrator.

0003 Operating environment setting error INI file does not exist.
Reinstall the EMPS.
If the error occurs again, contact the administrator.

0004 Operating environment setting error INI file invalid

Reinstall the EMPS.
If the error occurs again, contact the administrator.

Connection Command Screen

0005 The CD-ROM drive does not exist. No CD drive
0006 The CD cannot be read. CD read failure
0007 The CD has not been inserted. Insert the CD and click [Retry] button. CD insertion retry
0008 Data read error MDB file copy failure
Check the CD and CD drive.
If the error occurs again, contact the administrator.

0009 Data read error CD version file copy failure

Check the CD and CD drive.
If the error occurs again, contact the administrator.

0010 Data read error CD version file read failure

Check the CD and CD drive.
If the error occurs again, contact the administrator.

0011 Data read error MDB Open failure

Check the CD and CD drive.
If the error occurs again, contact the administrator.

Mode Select Screen

0012 Service address of OEM master cannot be obtained. OEM master service address read
failure
User Authentication Screen
0013 Enter your ID. ID input
0014 Enter your PASSWORD. Password input
0015 Enter the PASSWORD for compulsory reflash. Password for compulsory reflash
input
0016 ID and PASSWORD are invalid. ID + Password
0017 The PASSWORD for compulsory reflash is invalid. Password for compulsory reflash
analysis error
0018 The PASSWORD for compulsory reflash is invalid. Password for compulsory reflash and
ID
0019 The PASSWORD for compulsory reflash has expired. Password for compulsory reflash
expiration date
0020 Service address of OEM master cannot be obtained. OEM master service address read
failure
OEM Manufacturer Selection Screen
0021 Select the machine's manufacturer and click "OK". Select OEM
 Electronic control fuel injection system (Common rail type) 1E-127

Connection Confirmation Screen

0022 Enter the COM port. Port input
0023 Select transmission bit rate. Transmission bit rate selection
0024 Setting of COM port is invalid. Input port invalid digit number
0025 Setting of COM port is invalid. Input port invalid number
0026 Communication setting is invalid. Invalid communication setting
0027 Process was terminated last time (P_DATE). Do you want to continue? Previous file exits.
0028 Previous ECM Parts Number information will be deleted. Is it OK? Previous file deletion confirmation
0177 Setting of COM port is invalid. Invalid port (communication setting)
Selector S/N Reading (1st time)
0029 Selector S/N Request cannot be sent. Selector S/N request failure
0030 This is unconfirmed selector. Check the selector. Unconfirmed

0031 User ID does not correspond to selector S/N. User ID verification

Confirm user ID again.
0032 Communication error Incorrect number of digits in S/N
If the error occurs again, contact the administrator.
0033 Communication error Command error (receiver)
If the error occurs again, contact the administrator.
0034 Communication error BCC error (receiver)
If the error occurs again, contact the administrator.
0035 Communication error Command error reception
If the error occurs again, contact the administrator.
0036 Communication error BCC error reception
If the error occurs again, contact the administrator.
0037 Communication error Time-out error reception
If the error occurs again, contact the administrator.
0038 Communication error Other error reception
If the error occurs again, contact the administrator.
0039 Communication error Communication error (interrupt
If the error occurs again, contact the administrator. signal)
0040 Communication error Communication error (frame error)
If the error occurs again, contact the administrator.
0041 Communication error Communication error (port overrun)
If the error occurs again, contact the administrator.
0042 Communication error Communication error (receive buffer
If the error occurs again, contact the administrator. overflow)
0043 Communication error Communication error (parity error)
If the error occurs again, contact the administrator.
0044 Communication error Communication error (the send buffer
If the error occurs again, contact the administrator. is full)
0045 Communication error Communication error (DCB error)
If the error occurs again, contact the administrator.
0046 Communication error Communication other error
If the error occurs again, contact the administrator.
0047 Communication error No response from selector
If the error occurs again, contact the administrator.
1E-128 Electronic control fuel injection system (Common rail type)

Former Parts Number Reading (1st time)

0048 ECM Parts Number Request cannot be sent. Parts number request failure
0049 Communication error Invalid number of digits for Parts
If the error occurs again, contact the administrator. number
0050 Record of current Parts Number does not exist. Either former or current code does not
The Parts Number will be confirmed again. Clicking the [OK] button returns to Main exist.
Menu.
0051 Record of current Parts Number does not exist. Record acquisition error
The Parts Number will be confirmed again. Clicking the [OK] button returns to Main
Menu.
0052 Service address does not correspond. Do you want to search again? Service address retry
0053 ECM Parts Number Request cannot be sent. Parts number request failure of service
address retry
0054 Current ECM Parts Number cannot be obtained. Integrated confirmation process
Do you want to execute an integrated confirmation process?
0055 Integrated confirmation process takes about 60 minutes. Do you want to execute this 60-minute process execution
process? confirmation
0056 Current ECM Parts Number could not be obtained. 60-minute process result error
This ECM needs compulsory reflash.
If the ECM Parts Number cannot be obtained even after compulsory reflash, the
ECM may be damaged.
Program will be ended.
0057 Communication error Command error (receiver)
If the error occurs again, contact the administrator.
0058 Communication error BCC error (receiver)
If the error occurs again, contact the administrator.
0059 Communication error Command error reception
If the error occurs again, contact the administrator.
0060 Communication error BCC error reception
If the error occurs again, contact the administrator.
0061 Communication error Time-out error reception
If the error occurs again, contact the administrator.
0062 Communication error Other error reception
If the error occurs again, contact the administrator.
0063 Communication error Communication error (interrupt
If the error occurs again, contact the administrator. signal)
0064 Communication error Communication error (frame error)
If the error occurs again, contact the administrator.
0065 Communication error Communication error (port overrun)
If the error occurs again, contact the administrator.
0066 Communication error Communication error (receive buffer
If the error occurs again, contact the administrator. overflow)
0067 Communication error Communication error (parity error)
If the error occurs again, contact the administrator.
0068 Communication error Communication error (the send buffer
If the error occurs again, contact the administrator. is full)
0069 Communication error Communication error (DCB error)
If the error occurs again, contact the administrator.
0070 Communication error Communication other error
If the error occurs again, contact the administrator.
0071 Communication error No response from selector
If the error occurs again, contact the administrator.
 Electronic control fuel injection system (Common rail type) 1E-129

New Parts Number Search Screen

0072 Select “ENGINE MODEL”, “ENGINE TYPE” from pull-down menu respectively, Engine model selection
and click [Select] button.
0073 Select “ENGINE MODEL”, “ENGINE TYPE” from pull-down menu respectively, Engine type selection
and click [Select] button.
0074 Select “OEM NAME” from pull-down menu. Select OEM
0075 Enter the six-digit number into the "ENGINE NUMBER" field. Engine number input
0076 ECM Parts Number cannot be found. Appropriate new Parts number does
not exist.
New Parts Number Search Result Confirmation Screen
0077 Enter new ECM Parts Number. New Parts number input
0078 Record of former ECM Parts Number to be reflashed compulsorily does not exist. No new record for compulsory reflash
0079 ECM Parts Number is not compatible. No compatible code exist.
0080 Enter search condition for ECM Parts Number. OEM refined selection
0081 New ECM Parts Number cannot be identified. Refinement is not possible.
Rewriting Result Confirmation Screen
0082 The CD cannot be read. CD cannot be read.
0083 The CD has not been inserted. Insert the CD and click [Retry] button. CD insertion retry
0084 The CD, which is inserted, may be different from one used to start this program, or CD version cannot be obtained.
may be damaged.
Program will be ended in this status. Check the CD and start the program again to
restart the process.
0085 Setting of the program file does not exist. Program file cannot be obtained for
Reflash cannot be processed. Select again. this record.
0086 The CD, which is inserted, may be different from one used to start this program, or Program file cannot be decompressed.
may be damaged.
Program will be ended in this status. Check the CD and start the program again to
restart the process.
READY LED (ON)
0087 Check the switch status. LED does not come on.
Rewriting Initialization Process
- During execution -
0088 Reflash error Being processed (all)
Do you want to try reflash again?
0089 Reflash error Invalid start up parameter (all)
Do you want to try reflash again?
0090 Reflash error Thread start up failure (all)
Do you want to try reflash again?
0091 Reflash error Unknown
Do you want to try reflash again?
- At CALL BACK -
0092 Reflash error No response from rewriting module
Do you want to try reflash again?
0093 Reflash error Port open error (all)
Do you want to try reflash again?
0094 Reflash error Communication error (all)
Do you want to try reflash again?
0095 Reflash error Time out (all)
Do you want to try reflash again?
0096 Reflash error Flash memory cannot be erased with
Do you want to try reflash again? boot mode (at initializing only).
0097 Reflash error Unknown
Do you want to try reflash again?
1E-130 Electronic control fuel injection system (Common rail type)

Rewriting Reflashing Process

- During execution -
0098 Reflash error Being processed (all)
Do you want to try reflash again?
0099 Reflash error Inconsistent execution state (at writing
Do you want to try reflash again? and verifying)
0100 Reflash error Invalid start up parameter (all)
Do you want to try reflash again?
0101 Reflash error Thread start up failure (all)
Do you want to try reflash again?
0102 Reflash error Unknown
Do you want to try reflash again?
- At CALL BACK -
0103 Reflash error No response from rewriting module
Do you want to try reflash again?
0104 Reflash error User program file cannot be found (at
Do you want to try reflash again? writing and verifying).
0105 Reflash error Invalid user program file (at writing
Do you want to try reflash again? and verifying)
0106 Reflash error No data to be written to flash memory
Do you want to try reflash again? (at writing and verifying)
0107 Reflash error Clause error (at writing and verifying)
Do you want to try reflash again?
0108 Reflash error Port open error (all)
Do you want to try reflash again?
0109 Reflash error Communication error (all)
Do you want to try reflash again?
0110 Reflash error Time out (all)
Do you want to try reflash again?
0111 Reflash error Writing error (at writing only)
Do you want to try reflash again?
0112 Reflash error Unknown
Do you want to try reflash again?
 Electronic control fuel injection system (Common rail type) 1E-131

Rewriting Verification Process

- During execution -
0113 Reflash error Being processed (all)
Do you want to try reflash again?
0114 Reflash error Inconsistent execution state (at writing
Do you want to try reflash again? and verifying)
0115 Reflash error Invalid start up parameter (all)
Do you want to try reflash again?
0116 Reflash error Thread start up failure (all)
Do you want to try reflash again?
0117 Reflash error Unknown
Do you want to try reflash again?
- At CALL BACK -
0118 Reflash error No response from rewriting module
Do you want to try reflash again?
0119 Reflash error User program file cannot be found (at
Do you want to try reflash again? writing and verifying).
0120 Reflash error Invalid user program file (at writing
Do you want to try reflash again? and verifying)
0121 Reflash error No data to be written to flash memory
Do you want to try reflash again? (at writing and verifying)
0122 Reflash error Clause error (at writing and verifying)
Do you want to try reflash again?
0123 Reflash error Port open error (all)
Do you want to try reflash again?
0124 Reflash error Communication error (all)
Do you want to try reflash again?
0125 Reflash error Time out (all)
Do you want to try reflash again?
0126 Reflash error Verification error (at verification only)
Do you want to try reflash again?
0127 Reflash error Unknown
Do you want to try reflash again?
READY LED (OFF)
0128 Check the switch status. LED not off
1E-132 Electronic control fuel injection system (Common rail type)

Selector S/N Reading (2nd time)

0129 Selector S/N Request cannot be sent. Selector S/N request failure
0130 Communication error Incorrect number of digits in S/N
If the error occurs again, contact the administrator.
0131 The device, which is different from one used to read the ECM Parts Number, is Differ from the first time
connected.
This ECM cannot operate properly. Do you want to try the process again?
0132 Process will be terminated. Abort
Connect the selector correctly and try again.
0133 Communication error Command error (receiver)
If the error occurs again, contact the administrator.
0134 Communication error BCC error (receiver)
If the error occurs again, contact the administrator.
0135 Communication error Command error reception
If the error occurs again, contact the administrator.
0136 Communication error BCC error reception
If the error occurs again, contact the administrator.
0137 Communication error Time-out error reception
If the error occurs again, contact the administrator.
0138 Communication error Other error reception
If the error occurs again, contact the administrator.
0139 Communication error Communication error (interrupt
If the error occurs again, contact the administrator. signal)
0140 Communication error Communication error (frame error)
If the error occurs again, contact the administrator.
0141 Communication error Communication error (port overrun)
If the error occurs again, contact the administrator.
0142 Communication error Communication error (receive buffer
If the error occurs again, contact the administrator. overflow)
0143 Communication error Communication error (parity error)
If the error occurs again, contact the administrator.
0144 Communication error Communication error (the send buffer
If the error occurs again, contact the administrator. is full)
0145 Communication error Communication error (DCB error)
If the error occurs again, contact the administrator.
0146 Communication error Communication other error
If the error occurs again, contact the administrator.
0147 Communication error No response from selector
If the error occurs again, contact the administrator.
 Electronic control fuel injection system (Common rail type) 1E-133

New Parts Number Reading (2nd time)

0148 ECM Parts Number Request cannot be sent. Parts number request failure
0149 Communication error Invalid number of digits for Parts
If the error occurs again, contact the administrator. number
0150 Reflashed ECM Parts Number does not correspond to the entered/selected ECM Differ from the entry value
Parts Number.
0151 Service address does not correspond. Do you want to search again? Service address retry
0152 ECM Parts Number Request cannot be sent. Parts number request failure of service
address retry
0153 Current ECM Parts Number cannot be obtained. Integrated confirmation process
Do you want to execute an integrated confirmation process?
0154 Integrated confirmation process takes about 60 minutes. Do you want to execute this 60-minute process execution
process? confirmation
0155 Current ECM Parts Number could not be obtained. 60-minute process result error
This ECM needs compulsory reflash.
If the ECM Parts Number cannot be obtained even after compulsory reflash, the
ECM may be damaged.
Program will be ended.
0156 Communication error Command error (receiver)
If the error occurs again, contact the administrator.
0157 Communication error BCC error (receiver)
If the error occurs again, contact the administrator.
0158 Communication error Command error reception
If the error occurs again, contact the administrator.
0159 Communication error BCC error reception
If the error occurs again, contact the administrator.
0160 Communication error Time-out error reception
If the error occurs again, contact the administrator.
0161 Communication error Other error reception
If the error occurs again, contact the administrator.
0162 Communication error Communication error (interrupt
If the error occurs again, contact the administrator. signal)
0163 Communication error Communication error (frame error)
If the error occurs again, contact the administrator.
0164 Communication error Communication error (port overrun)
If the error occurs again, contact the administrator.
0165 Communication error Communication error (receive buffer
If the error occurs again, contact the administrator. overflow)
0166 Communication error Communication error (parity error)
If the error occurs again, contact the administrator.
0167 Communication error Communication error (the send buffer
If the error occurs again, contact the administrator. is full)
0168 Communication error Communication error (DCB error)
If the error occurs again, contact the administrator.
0169 Communication error Communication other error
If the error occurs again, contact the administrator.
0170 Communication error No response from selector
If the error occurs again, contact the administrator.
1E-134 Electronic control fuel injection system (Common rail type)

Campaign
0171 Campaign log could not be output. Campaign decoding error
0172 Campaign log could not be output. Campaign file coupling error
0173 Campaign log could not be output. No file being coupled for campaign
0174 Campaign log could not be output. Encryption error
0175 Desktop folder could not be obtained. Desktop cannot be obtained.
0176 File copy cannot be performed. Desktop cannot be copied.
 Electronic control fuel injection system (Common rail type) 1E-135

How to use breaker box

Breaker box inspection procedure Important:
The breaker box is a tool to easily check open or short When inspecting or measuring the voltage and
circuit in connector pin and harness between ECM and continuity of ECM, be sure to use a adapter harness
each sensor or actuator, which used to be difficult to which is appropriate to the breaker box and the
check. Voltage and continuity on pins of ECM can be inspected machine
measured through breaker box using digital multi-meter • Before inspection and measurement of ECM
(5-8840-2691-0). If a scan tool is also used, more are performed, confirm the pin position.
precise inspection and service can be performed. Otherwise the ECM may get damaged.

Note:
The pin No. of ECM in diagnostic procedure
matches with the pin No. of breaker box.

1 2
A

TSWG0049

Name
1. Breaker box 2. Adapter harness

How to connect breaker box

Caution:
Be sure to turn off the key switch before the
connectors are disconnected.

1. Disconnect the ECM connector from ECM.

2. Connect the connector of adapter harness to ECM.
3. Connect the ECM connector to adapter harness.
4. Connect the adapter harness to breaker box.
1E-136 Electronic control fuel injection system (Common rail type)

3
1

TSWG0050

Name
1. Breaker box 3. ECM
2. Adapter harness 4. To machine-side harness

Caution: Example of use for breaker box

Take care with the following items when connecting 1. Inspection and measurement of voltage
the adapter harness to breaker box. Failure to
• Accelerator position sensor
connect may damage the ECM.
• Engine coolant temperature sensor
• Connect the connector on adapter harness • Intake air temperature sensor etc.
side to the connector of breaker box with the
same No. each other.
• When the connecting the connector, align the
cutouts of connector and breaker box each 3
other.

2 2

1
TSWG0052

Name
1. Breaker box
2. ECM
3. Digital multi-meter
TSWG0051

Name 2. Inspection and measurement of resistance

1. Connector No. (Adapter harness) • Crankshaft position sensor
2. Connector No. (Breaker box) • Camshaft position sensor
3. Cutout • SCV etc.
 Electronic control fuel injection system (Common rail type) 1E-137

TSWG0053

Name
1. Breaker box
2. ECM
3. Digital multi-meter

3. Inspection and measurement with oscilloscope

• Vehicle speed sensor signal
• Crankshaft position sensor signal
• Camshaft position sensor signal etc.

TSWG0054

Name
1. Breaker box
2. ECM
3. Oscilloscope

Caution:
During inspection and measurement, interference
of measurement lead on breaker box or mistaking
terminal to be measured may cause damage to
ECM or sensors. Work with extreme care.
1E-138 Electronic control fuel injection system (Common rail type)

Engine Control System

Description of function and operation

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

System control schematic diagram

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

Engine control module (ECM)

Accelerator position sensor input

CAN communication Machine control unit

Basic fuel injection amount

Boost pressure sensor input
CKP sensor input
CMP sensor input

Correction
Engine coolant temperature correction ECT sensor input
Barometric Pressure
Fuel temperature boost pressure correction
Correction between cylinders
Q-key correction
QR correction *

Correction Vehicle speed sensor input

SCV opening
time determination Injector coil energizing time
Timing determination

Common rail pressure sensor

Common rail

Injector coil

SCV

Injector

Supply pump

Fuel tank

TSHK0001
 Electronic control fuel injection system (Common rail type) 1E-139
About fuel injection correction
ECM calculates the basic injection amount based on
the signals from accelerator position sensor, boost
pressure sensor, CKP sensor, CMP sensor, etc. It
regulates the opening/closing period of SCV or electric
conduction of injector according to the common rail
pressure, engine coolant temperature, etc. at this time,

Fuel flow limit (mm 3/st)

to correct the optimum injection timing and injection
amount.
About starting Q adjust
ECM performs starting Q adjust when the engine speed
is less than the starting Q threshold value at engine
starting.
Also, ECM cannot perform starting Q adjust or start the
engine when the engine speed is less than the lowest
speed that system can recognize, since it does not Barometric pressure kPa(psi)
recognize engine rotation. highland
TSWG0173
Engine speed (rpm)

Starting Q threshold enginespeed

550

Minimum firing engine speed

60

30
System realization engine speed

TSWG0175

About high-altitude correction

ECM calculates the current altitude based on the
barometric pressure sensor signal.
It corrects the optimum fuel flow according to the
altitude etc. at this time.
1E-140 Electronic control fuel injection system (Common rail type)
Table of Input/Output

Injection control output

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

TSHK0002

Electronic control fuel injection system (Common Injection pressure control

rail type) The system controls the injection pressure by
The engine control module (ECM) gets information, controlling fuel pressure in common rail. It calculates
such as engine speed, engine load, etc. (signals from the appropriate pressure in common rail on the basis of
various sensors), and sends electrical signals, based engine speed, fuel injection amount, etc., and
on the information, to the supply pump, injector, etc. in discharges the proper amount of fuel by operating
order to properly control the fuel injection amount, supply pump resulting in pressure feed to common rail.
injection timing, etc. in each cylinder. Injection timing control
Injection amount control This is substitute for a timer function. The system
The system controls the injector, mainly based on the calculates the fuel injection timing on the basis of
signals from engine speed and accelerator opening mainly engine speed, injection amount, etc. and
angle or the designated speed of machine control unit, controls the injector.
to maintain the optimum injection amount. Injection rate control
To improve combustion in cylinders, the system injects
a little fuel (pre-injection) and ignites it at the beginning,
then perform the second injection (main injection) after
the first ignition. It controls these injection timing and
injection amount by operating the injector.
 Electronic control fuel injection system (Common rail type) 1E-141
Control during overheat
In overheating, ECM begins to limit fuel flow when the
engine coolant temperature exceeds 108°C (226°F), for
engine protection. It limits fuel flow further as the
engine coolant temperature goes up. Fuel flow is
limited to a certain level at around 120°C (248°F)*. (*
Setting varies depending on the machine manufacturer)
The system raises an alarm from 105°C (221°F) for
some machines. In addition to alarm, by reducing the
load to the machine, it enables to avoid such conditions
that the fuel flow is limited.

(226 )
100%
Fuel fiow

(248 )

(221 )
Engine coolant temperature

TSWG0169
1E-142 Electronic control fuel injection system (Common rail type)
System schematic diagram
4HK1

Common rail Pressure

pressure sensor Common rail limiter

Electromagnetic Fuel filter

pump
Flow damper

Supply pump

Pre filter

Injector

Fuel tank

Each sensor
Accelerator, Boost pressure,
Engine coolant temperature, etc.
CMP sensor CKP sensor

TSHK0037

6HK1

Common rail Pressure

pressure sensor Common rail limiter
Electromagnetic Fuel filter
pump

Flow damper

Supply pump

Pre filter

Injector

Fuel tank

Each sensor
Accelerator, Boost pressure,
Engine coolant temperature, etc.
CMP sensor CKP sensor

TSHK0038
 Electronic control fuel injection system (Common rail type) 1E-143
Fuel system
Fuel is supplied from fuel tank to supply pump, then
supplied to common rail after pressurized by the pump.
At this time, the system operates the suction control
valve (SCV) by the signal from ECM to control fuel
amount supplied to common rail.

2 4HK1

3
1

6
7

5 6HK1

TSHK0041

Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter

EGR (Exhaust gas recirculation) On 4HK1-TC and 6HK1-TC machines, the EGR system
Exhaust Gas Recirculation system is abbreviated to has the check valve to stop backward flow of EGR gas
EGR system. It recirculates part of exhaust gas into and flows it in one way direction, leading to increase the
intake manifold to mix an inert gas with intake air. This amount of EGR.
leads to lower the combustion temperature to limit
emissions of nitrogen oxide (NOx).
It controls amount of EGR by opening/closing the EGR
valve installed between exhaust manifold and intake
manifold. It determines amount of EGR, based on the
engine speed and load rate on engine (fuel injection
amount), and operates the EGR valve to control the
amount of EGR.
The cooling system (EGR cooler) equipped on the EGR
gas passage allows to cool down high temperature
EGR gas and mix it with new air to lower the
combustion temperature further, resulting in limiting
NOx effectively (Cooled EGR).
1E-144 Electronic control fuel injection system (Common rail type)
EGR control
ECM operates the motor according to engine speed,
engine load, etc. to control amount of EGR valve lift.
Amount of valve lift is detected by EGR position sensor.
The dark color area in the figure shows that the valve
lift amount is large, and the darkest color area shows
that the valve lift amount is almost 100%.

Accelerator position
No idle EGR

Engine speed

TSHK0066

EGR system schematic diagram

Outlet port of coolant Inlet port of coolant

EGR cooler

EGR valve

EGR valve position sensor

Exhaust

Boost temperature sensor

Engine control module (ECM)

Boost pressure sensor

Intake air
Intake air temperature sensor

Engine speed

ECT sensor

Engine load

TSWG0005
 Electronic control fuel injection system (Common rail type) 1E-145
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 speed.
automatically set the lowest idling speed to the DOWN
optimum value according to engine coolant While pressing the “DOWN” side of switch, the engine
temperature. speed decreases, resulting in decreasing the idling
speed. However, the idling speed does not decrease
Note: below the lowest speed.
Since specifications vary depending on each The engine speed controlled by idling control switch is
machine. Available functions also vary. stored in ECM when the key switch is turned to OFF.
The same speed can be achieved at the next operation.
Idling control selector switch
Using the “Idling control selector switch” allows to Speed limit control
switch the idling control function.
Speed limit control means that the engine control
Idling control switch module (ECM) controls fuel injection amount, based on
vehicle speed signal and engine speed, so that the
Using the “Idling control switch” allows to control the machine speed does not exceed the setting value.
idling speed. The vehicle speed signal is sent from vehicle speed
sensor to pulse matching box. The pulse matching box
Note:
corrects the signal to match with the machine, and
Refer to the machine’s manual for the locations of
sends it to ECM, meter, etc. The ECM recognizes the
idling control selector switch and idling control
engine speed by the signal from crankshaft position
switch.
(CKP) sensor.
The highest speed varies depending on engine
model, machine specifications and warm-up
condition of engine.

Meter,
Other ECU

Engine Fuel injection control Pulse

matching box

Engine speed signal

Vehicle speed sensor
1E-146 Electronic control fuel injection system (Common rail type)
Check for speed limit control
To check whether the speed limit control on the
machine is active, check blinking of diagnosis lamp.
Key ON
1. Turn the key switch to OFF. switch
and
2. Turn the key switch to ON. Engine
run OFF
3. Diagnosis lamp illuminates for 15 seconds and
then blinks three times.

1 sec
1

Diag
lamp
0

1 sec
15 sec
3 times

TSWG0006

Note:
If it does not blink, the speed limit control is not
active.

Engine speed output to tachometer

The engine control module (ECM) outputs the engine
speed pulse (4 pulses per engine revolution) as a
tachometer output to tachometer. Tachometer shows
the engine speed using the engine speed pulse sent
from ECM.

CAN Control unit

Engine speed Engine control communication Tachometer output
CKP sensor module (ECM) on machine side

Output from machine control unit by machine Tachometer

TSWG0119
 Electronic control fuel injection system (Common rail type) 1E-147
Preheating control
QOS (Quick On Start) system
The ECM determines the period required for glow (pre-
glow, glow, after-glow), and operates the glow relay and
QOS indicator lamp. QOS system allows to make the
starting at cold weather easier and reduce white smoke
and noise at starting. When turning the key switch to
ON, the ECM detects the engine coolant temperature
by signal from engine coolant temperature (ECT)
sensor and changes the period for glow so that the
proper starting conditions can be achieved all the time.
Also, after-glow function allows to stabilize idling
immediately after starting.

Key switch (ON)

Battery

Glow relay

Engine control module (ECM)

Glow plug
QOS indicator lamp
LCD or Lamp) Engine coolant temperature sensor

TSWG0007

Engine Control Module (ECM) The ECM monitors the information sent from various
sensors all the time and controls each system of the
About functions of ECM
powertrain. The ECM performs the diagnostic function
Note: of the system, detects operational problems of the
Refer to the machine’s manual for the locations of system, gives a warning through diagnosis lamp to a
ECM. driver and stores DTC (diagnostic trouble code). The
area where the trouble occurred can be identified by
the DTC to assist a mechanic to perform repair work.
The ECM sends the voltage of 5 V to supply the power
to various sensors or switches. The ECM controls the
output circuits by controlling the ground or power
supply circuit through a certain device.

ECM and components

The ECM is designed to maintain the level of emission
as the emission control regulations and get a good
performance and fuel efficiency at the same time. The
ECM monitors various functions of the engine through
the sensors such as crankshaft position (CKP) sensor
etc.

TSWG0008
1E-148 Electronic control fuel injection system (Common rail type)
ECM voltage Removal of ECM
The ECM energizes standard voltage to various 1. Turn the key switch to OFF.
switches and sensors. The resistance value of the ECM 2. Disconnect the battery cable from negative
is quite high so that the ECM can energize a voltage terminal.
like this. The voltage actually applied to the circuit is 3. Remove the parts (relay etc.) around the ECM to
low, and it does not sometimes comes on even if the facilitate removal of it.
test light is connected to the circuits. The voltmeter
4. Disconnect the ECM connector from ECM. (81-pin,
usually used in a service shop may not indicate a
40-pin connectors)
correct reading because the input impedance is too low.
A digital multi-meter which has an input impedance of 5. Loosen the installing bolts (nuts) and remove the
10 MΩ (e.g. 5-8840-2691-0) should be used to get an ECM.
correct reading of the voltage.
Note:
Installation method and locations vary depending
Electrically erasable programmable read only
on each machine. Refer to the machine’s manual.
memory (EEPROM)
EEPROM has programs which is necessary for ECM to Installation of ECM
control the operation of powertrain and information for
Install the ECM in the reverse order of removal.
calibration.
EGR valve position learning is required after replacing
If fault is found in the EEPROM, replace the ECM.
the ECM.
Examples of programs to control powertrain and
information for calibration in ECM are the following 1. Turn the key switch to “ON”.
items. 2. Turn the key switch to “OFF”.
• Engine model 3. Leave as it is for 10 seconds.
• Engine number Failure to perform the EGR valve position learning may
result in detection of DTC for EGR.
• ECM part number
• DTC About ECM power off
• Learning value for interval correction of cylinders
The power supply inside the ECM does not go off for
• QR about 10 seconds after turning the key switch OFF. If
• Q-key the ECM power needs to be off such as for memory
• Learning value for EGR correction clear, wait for more than 10 seconds after turning the
key switch OFF.
Precautions on ECM service work

Note:
• Be sure to use the ECM with the part number
corresponding to the machine.
• If performing welding on the machine,
disconnect the battery cable from the negative Key switch
ON
terminal beforehand.

The ECM is designed to sustain normal consumption of

current relating to the operation of the machine. Circuits
Key switch
should not be overloaded. In case of testing of open OFF
and short circuits, the circuits of the ECM must not be
connected to the ground or be supplied with voltage 10 sec

except that there is such an instruction. Be sure to use

a digital multi-meter (5-8840-2691-0) when performing
the tests of these circuits.

TSWG0176
 Electronic control fuel injection system (Common rail type) 1E-149
Engine component location diagram
(Component location, its form and parts to be used vary
depending on each machine.)
4HK1

13 12 11 10
7 6

9
1

2
8

3 4

TSHK0003
1E-150 Electronic control fuel injection system (Common rail type)
6HK1

13 12 11 10
7 6

2
8

3 4

TSHK0004

Name
1. Engine coolant temperature (ECT) sensor 8. Suction control valve (SCV)
2. Overheating switch 9. Fuel temperature (FT) sensor
3. Common rail pressure sensor 10. Boost temperature sensor
4. Engine oil pressure sensor 11. Boost pressure sensor
5. CKP sensor 12. Injector
6. CMP sensor 13. Glow plug
7. EGR valve
 Electronic control fuel injection system (Common rail type) 1E-151
Supply pump SCV (suction control valve)
4HK1 4HK1

2 1

TSHK0005 TSHK0007

6HK1 6HK1

1
3

TSHK0006 TSHK0008

Name Name
1. SCV 1. SCV
2. Fuel temperature (FT) sensor
3. Feed pump The SCV (suction control valve) is installed onto supply
pump section and controls pressure feed of fuel
The supply pump pressurizes fuel using engine output, (discharge amount) to common rail. The engine control
and pressure-feeds fuel to common rail. Supply pump module (ECM) regulates period of electric conduction
has also SCV (suction control valve), fuel temperature of SCV to regulate the fuel discharge amount.
(FT) sensor and feed pump.
Removal
Note: • Do not replace the SCV.
For work procedure, refer to “Engine section” in
• If it is faulty, replace it as supply pump ASM.
the service manual.
1E-152 Electronic control fuel injection system (Common rail type)
4HK1 Fuel temperature (FT) sensor

TSHK0127 TSWG0011

6HK1 The fuel temperature (FT) sensor is installed onto the

supply pump, and the thermistor changes the
resistance according to the temperature. The
resistance is low when the fuel temperature is high, and
is high when the temperature is low. The engine control
module (ECM) energizes the voltage (5 V) to the FT
sensor through pull up resistance, and calculates fuel
temperature based on change of voltage to use for
various controls such as supply pump control etc. If the
resistance is low (temperature is high), the voltage
becomes low; if the resistance is high (temperature is
low), the voltage becomes high.

Removal
• Do not replace the FT sensor.
• If it is faulty, replace it as supply pump ASM.

TSHK0111

TSHK0110
 Electronic control fuel injection system (Common rail type) 1E-153
Common rail Flow damper
4HK1 4HK1

4 4

3 3

1 2 1 2

TSHK0009 TSHK0009

6HK1 6HK1

4 4

3 3

1 2 1 2

TSHK0010 TSHK0010

Name Name
1. Common rail 1. Common rail
2. Common rail pressure sensor 2. Common rail pressure sensor
3. Pressure limiter 3. Pressure limiter
4. Flow damper 4. Flow damper

The common rail receives fuel from supply pump, holds The flow damper is installed onto outlet port to each
the common rail (fuel) pressure and distributes fuel to injector of common rail, limits pressure pulsation in
each cylinder. The common rail has common rail common rail and prevents over-injected fuel from
pressure sensor, flow damper and pressure limiter. injector. When the flow damper operates, fuel supply to
injector is stopped.
Note:
For work procedure, refer to “Engine section” in Removal
the service manual. • Do not replace the flow damper.
• If it is damaged, replace it as common rail ASM.
1E-154 Electronic control fuel injection system (Common rail type)
Pressure limiter Common rail pressure sensor
4HK1 4HK1

4 4

3 3

1 2 1 2

TSHK0009 TSHK0009

6HK1 6HK1

4 4

3 3

1 2 1 2

TSHK0010 TSHK0010

Name Name
1. Common rail 1. Common rail
2. Common rail pressure sensor 2. Common rail pressure sensor
3. Pressure limiter 3. Pressure limiter
4. Flow damper 4. Flow damper

The pressure limiter operates to release the pressure in The common rail pressure sensor is installed onto
common rail when the pressure becomes extremely common rail, detects fuel pressure in common rail,
high. converts the pressure into the voltage signal and sends
it to engine control module (ECM). Voltage becomes
Removal higher as pressure becomes higher, and lower as one
• Do not replace the pressure limiter. does lower. ECM calculates the actual common rail
• If it is damaged, replace it as common rail ASM. pressure (fuel pressure) based on the voltage signal
sent from sensors and uses it for fuel injection control
etc.
 Electronic control fuel injection system (Common rail type) 1E-155
Removal Injector
• Do not replace the common rail pressure sensor.
• If it is damaged, replace it as common rail ASM.
4HK1

The injector is installed onto cylinder head section and

is controlled by engine control module (ECM) to inject
TSHK0121 fuel. The ECM raises the voltage for operating injectors
internally, energizes to injector, and regulates period of
6HK1
electric conduction of injector to control fuel injection
amount and injection timing.

Note:
For work procedure, refer to “Engine section” in
the service manual.

Engine coolant temperature (ECT) sensor

TSHK0112

TSWG0017
1E-156 Electronic control fuel injection system (Common rail type)
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.
Resistance is low at high engine coolant temperature
and high at low engine coolant temperature. The
engine control module (ECM) energizes the voltage (5
V) to the ECT sensor through pull up resistance, and
calculates engine coolant temperature based on
change of voltage to use for various controls such as
fuel injection etc. If the resistance is low (temperature is
high), the voltage becomes low; if the resistance is high
(temperature is low), the voltage becomes high.

Removal
• Disconnect the connector and remove it with
19mm-wrench

TSWG0019

The crankshaft position (CKP) sensor is installed onto

flywheel housing and produces the CKP signal when
the convex portion of flywheel passes the sensor. The
engine control module (ECM) distinguishes the
19mm
cylinders by the CMP signal input from CMP 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 signal.
However it is done by CMP sensor if the CKP sensor is
faulty.

Removal
• Disconnect the connector, and remove the 10mm-
TSHK0116
mounting bolt and sensor.

Installation 4HK1
• Apply Loctite 572 before installing it.
Tightening torque: 19.6 — 29.4 N⋅m {2 — 3 kg⋅m/
14 — 22 lb⋅ft}

10mm

TSHK0123
 Electronic control fuel injection system (Common rail type) 1E-157
6HK1 6HK1

15
10mm
1

TSHK0118 TSWG0152

Installation The camshaft position sensor is installed onto the rear

of cylinder head and produces the CMP signal when
• Tightening torque: 14.7 — 24.5 N⋅m {1.5 — 2.5
the cam portion of camshaft passes the sensor. The
kg⋅m/11 — 18 lb⋅ft}
engine control module (ECM) distinguishes the
cylinders by the CMP signal input from CMP sensor,
Camshaft position (CMP) sensor
determines the crank angle and uses it to control fuel
4HK1 injection and calculate the engine speed. These
controls are performed, usually based on CKP signal.
However it is done by CMP sensor if the CKP sensor is
faulty.

Removal
• Scissors gear is installed to the cam gear of 6HK1
engine. When the cam gear has been removed,
ensure that the scissors gear is installed properly.
15 • Disconnect the connector, and remove the 10mm-
mounting bolt and sensor.
1 4HK1

TSHK0040

10mm

TSHK0124
1E-158 Electronic control fuel injection system (Common rail type)
6HK1 4HK1

10mm

27mm

TSHK0117 TSHK0122

Installation 6HK1
• Apply a coat of engine oil to the O-ring.
Tightening torque: 7.8±2N⋅m {0.8±0.2 kg⋅m/69±18
lb⋅in}

Engine oil pressure sensor

27mm

TSHK0109

Installation
• Tightening torque: 41 N⋅m{4.2 kg⋅m/30 lb⋅ft}

Accelerator position (AP) sensor

TSWG0067
The accelerator position (AP) sensor is installed onto
The engine oil pressure sensor is installed near the machine console panel and supplies the voltage signal,
starter motor of the cylinder block; it detects engine oil which changes according to the accelerator volume
pressure, converts the pressure into the voltage signal angle, to engine control module (ECM). The ECM
and sends it to engine control module (ECM). Voltage calculates accelerator position by voltage signal and
becomes higher as pressure becomes higher, and use it for various controls such as fuel injection amount
lower as one does lower. control.
Removal Note:
• Disconnect the connector and remove it with 27 Refer to the machine’s manual for the location of
mm-wrench accelerator position sensor.
 Electronic control fuel injection system (Common rail type) 1E-159
Barometric pressure sensor Note:
Refer to the machine’s manual for the location of
intake air temperature (IAT) sensor.

EGR position sensor

TSWG0020

The barometric pressure sensor is installed onto the

machine side and converts the barometric pressure into
voltage signal. The ECM calculates barometric TSWG0149
pressure by voltage signal and performs fuel injection
amount correction (high-altitude correction) etc. by It is installed in EGR valve and detects the valve lift
barometric pressure. amount of EGR.

Note: Note:
Refer to the machine’s manual for the location of Do not disassemble the EGR position sensor. If it is
barometric pressure sensor. faulty, replace it as EGR valve ASM.

Intake air temperature (IAT) sensor Removal

4HK1

The intake air temperature (IAT) sensor is installed onto

TSHK0125
the machine side and detects the temperature of intake
air for optimum fuel injection control.

Tightening torque: 10.8 — 16.3 N⋅m {1.1 — 1.7 kg⋅m/96

— 144 lb⋅in}
1E-160 Electronic control fuel injection system (Common rail type)
6HK1

10mm

TSHK0113

TSHK0115
Installation
• Tightening torque: 4 — 6 N⋅m {0.4 — 0.6 kg⋅m/35
Boost pressure sensor — 53 lb⋅ft}

Boost temperature sensor

TSWG0022

The boost pressure sensor uses the pressure hose

between the boost pressure sensor and intake pipe,
detects boost (intake air pressure), converts the The boost temperature sensor is installed onto the EGR
pressure into the voltage signal and sends it to engine valve upstream side of intake manifold. The sensor is
control module (ECM). Voltage becomes higher as thermistor type. The resistance in the sensor changes
pressure becomes higher, and lower as one does as the temperature changes.
lower. ECM calculates the boost (intake air pressure)
based on the voltage signal sent from sensors and Removal
uses it for fuel injection control etc. • Disconnect the connector and remove it with 19
mm-wrench
Removal
• Disconnect the connector, and remove the two
10mm-mounting bolts, hoses and sensor.
 Electronic control fuel injection system (Common rail type) 1E-161
4HK1 DLC (data link connector)

19mm

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16

TSHK0126 TSWG0023

6HK1 The DLC (data link connector) is a connector for

communication and connection between the external
diagnostic device (scan tool) and each controller.

Note:
Refer to the machine’s manual for the locations of
DLC.

Diagnostic switch
19mm
The diagnosis switch shorts the DLC terminals No. 1
and No. 4 (or No. 5) to make the diagnosis lamp blink to
indicate DTC.

Note:
Refer to the machine’s manual for the locations and
form of diagnosis switch.

Memory clear switch

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

Diagnosis lamp Mode selector switch (1, 2, 3)

It indicates DTC by blinking after the diagnosis switch is The mode selector switch allows to operate at the
turned to ON. engine speed set by each mode.

Note: Note:
Refer to the machine’s manual for the locations of Refer to the machine’s manual for the locations of
diagnosis lamp. mode selector switch.
1E-162 Electronic control fuel injection system (Common rail type)
Wiring diagram of engine control module (ECM)
(*: Refer to the machine’s manual for fuse capacity.)
4HK1

(15A)*
24
Engine stop switch 107 CKP sensor
47 106
Diagnostic lamp
6 108
Engine oil pressure lamp
17
Key switch

QOS indicator lamp 80

11 67 Engine oil
pressure sensor
(ON)

Boost temperature lamp 79

7
10 84 Engine coolant
temperature sensor
(50A)*

Glow relay
83
Fuel temperature
sensor

Glow plug
(60A)* 99
CMP sensor
98
100
Key switch

Main relay 21 87
40 82
(ST)

(30A)* Common rail

2 90
101 pressure sensor
5
(10A)*

94 U
EGR valve
93 V
(30A)* position sensor
92 W
2
(100A)*

Vehicle speed
19
Fuel pump relay sensor

121
Battery

(10A)*

Fuel pump Injector #1

119
ECM

M
Charge 117 Injector #4
lamp O/H lamp O/H switch

116
Generator
R Injector #3
L 120
Safty relay B terminal
E Sterter 118 Injector #2

R S S terminal SCV
B C B terminal 105
113
89
97
42
Accelerator
63 8 Tachometer
position
sensor 64
41
20 18
Barometric 61 37
pressure 71
sensor 60

Intake air 72
temperature 38 7 TOOL
sensor
72 52 1
Data link connector
Boost 95 4
pressure 91 5
sensor 109
Boost 74
temperature 81
sensor
43

U 111 62
EGR valve V
M 103 1
motor W 110
3
Memory clear switch 32 4

TSHK0011
 Electronic control fuel injection system (Common rail type) 1E-163
6HK1

(15A)*
24 107 CKP sensor
Engine stop switch 106
47
Diagnostic lamp 6 108
Engine oil pressure lamp
Key switch

17 80
QOS indicator lamp 67 Engine oil
11 pressure sensor
79
(ON)

Boost temperature lamp

7
84 Engine coolant
10
temperature sensor
(50A)*

Glow relay 83 Fuel temperature

sensor

Glow plug 99
(60A)* CMP sensor
98
100
87
Key switch

Main relay
21
82
40 Common rail
(ST)

(30A)* 90
2 101 pressure sensor

5
(10A)*

94 U EGR valve
93 V position sensor
92 W
46
(100A)*

19 Vehicle speed
Fuel pump relay sensor
121

Injector #1
119
Battery

(10A)*

Fuel pump
114 Injector #2
ECM

M
Charge
lamp O/H lamp O/H switch
117 Injector #3

116
Generator
R
L Injector #4
115
Safty relay B terminal
E Sterter Injector #5
120
R S S terminal
B C B terminal Injector #6
118
SCV
105
42 113
Accelerator
position 63 89
sensor 64 97
41
20 8 Tachometer
Barometric 61
pressure 71
sensor 60 18
37
Intake air 72
temperature
sensor
38 7 TOOL
Boost 95
52 1 Data link connector
pressure 91
sensor 109 4
5
Boost 74
temperature 81
sensor
43

U 111 62
EGR valve V 103
M 1
motor W 110
3
Memory clear switch
32 4

TSHK0036
1E-164 Electronic control fuel injection system (Common rail type)
Pin arrangement of engine control module (ECM)

TSWG0026

81-pin connector

Pin No. Terminal name Connection

1 PG-POWER GND
2 PS-+B Power supply
3 PG-POWER GND
4 PG-POWER GND
5 PS-+B Power supply
6 OS-DIAGL Diagnosis lamp
7 OS-BOOSTL Boost temperature sensor pilot lamp
8 — —
9 — —
10 OS-GLOWR Glow relay
11 OS-GLOWL QOS indicator lamp
 Electronic control fuel injection system (Common rail type) 1E-165

Pin No. Terminal name Connection

12 — —
13 — —
14 — —
15 — —
16 — —
17 OS-OILPL Engine oil pressure lamp
18 CC-CAN-H CAN-HIGH
19 IF-SPD Vehicle speed sensor signal
20 SG-SLD1 Accelerator position sensor 1 GND
21 OS-MAINR ECM main relay
22 — —
23 — —
24 IS-IGKEY Key switch ON signal
25 — —
26 — —
27 — —
28 — —
29 — —
30 — —
31 — —
32 IS-MEMCL Memory clear switch
33 — —
34 — —
35 — —
36 — —
37 CC-CAN-L CAN-LOW
38 CC-KW2000 Data link connector
39 — —
40 OS-MAINR ECM main relay
41 SG-5VRT1 Accelerator position (AP) sensor GND
42 SP-5V1 Accelerator position (AP) sensor power supply
43 PG-SIGN GND
44 — —
45 — —
46 IS-START Key switch start signal
47 ENGSTP Engine stop switch
48 — —
49 — —
50 — —
1E-166 Electronic control fuel injection system (Common rail type)

Pin No. Terminal name Connection

51 — —
52 IS-DIAG Diagnostic switch
53 — —
54 — —
55 — —
56 — —
57 — —
58 — —
59 — —
60 SG-5VRT2 Barometric pressure sensor, intake air temperature (IAT) sensor GND
61 SP-5V2 Barometric pressure sensor power supply
62 PG-SIGN GND
63 IA-ACCEL1 Accelerator position (AP) sensor 1 signal
64 IA-ACCEL2 Accelerator position (AP) sensor 2 signal
65 — —
66 — —
67 IA-OILPRESS Engine oil pressure sensor signal
68 — —
69 — —
70 — —
71 IA-BARO Barometric pressure sensor signal
72 IA-IAT Intake air temperature sensor signal
73 — —
74 IA-THBST Boost temperature signal
75 — —
76 — —
77 — —
78 — —
79 SG-5VRT3 Engine oil pressure sensor, fuel temperature sensor, engine coolant
temperature sensor GND
80 SP-5V3 Engine oil pressure sensor power supply
81 PG-CASE GND

40-pin connector

Pin No. Terminal name Connection

82 IA-PFUEL Common rail pressure sensor signal
83 IA-THL Fuel temperature sensor signal
84 IA-THW Engine coolant temperature sensor signal
85 — —
 Electronic control fuel injection system (Common rail type) 1E-167

Pin No. Terminal name Connection

86 — —
87 SP-5V5 Camshaft position (CMP) sensor power supply
88 — —
89 IA-SCVLO PCVLO drive
90 IA-PFUEL Common rail pressure sensor signal
91 IA-BPRESS Boost pressure sensor signal
92 IA-EBMPOS3 EGR valve EGR position sensor W
93 IA-EBMPOS2 EGR valve EGR position sensor V
94 IA-EBMPOS1 EGR valve EGR position sensor U
95 SP-5V4 Boost pressure sensor power supply
96 — —
97 IA-SCVLO PCVLO drive
98 IF-CAMHAL Camshaft position (CMP) sensor signal
99 SP-CAMHAL Camshaft position (CMP) sensor power supply
100 SG-SLD5 Camshaft position (CMP) sensor, common rail pressure sensor shield
101 SG-5VRT5 Common rail pressure sensor GND
102 — —
103 OM-EBM2 EGR valve DC servomotor power supply input V
104 — —
105 OS-SCVHI SCVHI drive
106 IF-CRANK- Crankshaft position (CKP) sensor (−)
107 IF-CRANK+ Crankshaft position (CKP) sensor (+)
108 SG-SLD4 Crankshaft position (CKP) sensor shield
109 SG-5VRT4 Boost pressure sensor, engine coolant temperature sensor, fuel
temperature sensor GND
110 OM-EBM3 EGR valve DC servomotor power supply input W
111 OM-EBM1 EGR valve DC servomotor power supply input U
112 — —
113 OS-SCVHI SCVHI drive
114 OS-INJ5 Injector 2 (6H only)
115 OS-INJ6 Injector 4 (6H only)
116 OP-COM2 Injector power supply 2 (4H: No. 2, No. 3 cylinders/6H: No. 4, No. 5, No. 6
cylinders)
117 OS-INJ3 4H: Injector 4 /6H: Injector 3
118 OS-INJ4 4H: Injector 2 /6H: Injector 6
119 OS-INJ1 Injector 1
120 OS-INJ2 4H: Injector 3 /6H: Injector 5
121 OP-COM1 Injector power supply 1 (4H: No. 1, No. 4 cylinders/6H: No. 1, No. 2, No. 3
cylinders)
1E-168 Electronic control fuel injection system (Common rail type)
Circuit diagram
(Refer to “Wiring diagrams” for a way to read the diagram.)

Main relay circuit

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

Engine control module (ECM)

21 E-57
Main relay

40 E-57
E-57

B+
2
(30A)*

E-57

B+
5
(MAIN)*

Battery

TSWG0027
 4HK1
(100A)*

Starter
B

C
Battery
B

Generator

(15A)*
Starter for ECM control, glow circuit

(60A)*

Glow relay Starter relay Starter cut relay Main relay

(10A)*
1 H-22

5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START

10 E-57 Key switch 14 E-57

Engine control module (ECM)

Glow Glow relay control

plug

Starter cut relay signal

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

TSHK0012
Electronic control fuel injection system (Common rail type) 1E-169
 6HK1
(100A)*

Starter
B

C
Battery
B

Generator

(15A)*

(60A)*

Glow relay Starter relay Starter cut relay Main relay

(10A)*
1 H-22

5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1E-170 Electronic control fuel injection system (Common rail type)

1 H-1
OFF OFF
ON ON
START START

10 E-57 Key switch 14 E-57

Engine control module (ECM)

Glow Glow relay control

plug

Starter cut relay signal

TSWG0028
 Electronic control fuel injection system (Common rail type) 1E-171
Starter for safety relay, glow circuit
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)
4HK1

Engine control module (ECM)

(ON) (ST)
Br C

Key switch
ACC
B

START
OFF
ON
A

(ON) (ST)
BBr C
Safty relay

START
OFF

Glow relay control

ON
A
S
Starter

E-57
C

C
B

10
B

Glow
plug
Generator

Glow relay
B

L
(100A)*

(60A)*

H-22

B/W

H-1
5
1

1
(15A)*
Battery

TSHK0025
 6HK1

Starter
B

Battery B

Generator

(100A)* L

(15A)* (60A)*

B C
Safety relay

L S

Glow
relay

A A
1 H-22
B Br C B ACC Br C
5 (ON) (ST) (ON) (ST)
B/W
OFF OFF
ON ON
1E-172 Electronic control fuel injection system (Common rail type)

START START
1 H-1
Key switch
10 E-57

Engine control
module (ECM)
Glow relay
control

Glow
plug

TSWG0068
 CAN LOW CAN HIGH
Engine control
module (ECM)

KWP2000
CAN, GND, DLC circuits

52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57

1 FL-150 7 FL-150

DLC
Machine control unit

5 FL-150 4 FL-150

CAN HIGH CAN LOW

TSHK0013
Electronic control fuel injection system (Common rail type) 1E-173
 (15A)*

A A
Meter

Machine trouble Boost Charge O/H lamp

Diagnosis Engine oil QOS indicator Tachometer
diagnosis monitor temperature lamp
lamp pressure lamp lamp
lamp
Indicator lamp, tachometer circuit

3 H-6

1 E-164

Machine O/H switch

control unit

CAN LOW CAN HIGH

Generator
1E-174 Electronic control fuel injection system (Common rail type)

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

Engine control
module (ECM)

Diagnosis Engine oil pressure QOS indicator Boost temperature

lamp control lamp control lamp control lamp control

Tachometer signal
CAN HIGH CAN LOW
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

TSHK0014
 4HK1
Injector circuit

2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

Injector Injector Injector Injector

(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)

3 3
3 E-35 3 E-37 E-27 E-31

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

R L/Y L/R R W L L/W W

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

Engine control
Cylinder No. 3 Cylinder No. 2 Cylinder No. 1 Cylinder No. 4 module (ECM)

Feedback Feedback Feedback Feedback

B+ B+

TSHK0015
Electronic control fuel injection system (Common rail type) 1E-175
 6HK1

2 1 2 1 2 1 2 1 2 1 1 2
E-35 E-37 E-33 E-29 E-27 E-31

Injector Injector Injector Injector Injector Injector

(Cylinder No. 5) (Cylinder No. 6) (Cylinder No. 4) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 3)

3 3 3
3 E-35 3 E-37 3 E-33 E-29 E-27 E-31

3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94

3 H-95 7 H-95 6 H-95 2 H-95 4 H-95 3 H-94 7 H-94 2 H-94 6 H-94 4 H-94

1.25 0.75 0.75 0.75 1.25 1.25 0.75 0.75 0.75 1.25
R L/Y L/R G/B R W G/R L L/W W

3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12

1E-176 Electronic control fuel injection system (Common rail type)

116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

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

Feedback Feedback Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSWG0031
 SCV circuit

2 E-161

SCV

1 E-161

0.75 0.75
R/B R/W

1 H-6 2 H-6

97 E-56 89 E-56 105 E-56 113 E-56

Engine contorol
module (ECM)

B+

TSHK0016
Electronic control fuel injection system (Common rail type) 1E-177
 Vehicle speed Engine oil pressure
sensor signal 5V 5V sensor signal
5V

CKP CKP Engine coolant Vcc

HIGH LOW Fuel temperature temperature sensor
signal signal sensor signal signal

108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56
pressure sensor circuit

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

3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

2 E-98 1 E-98

Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A

* 3 E-90 Engine control

CAN LOW CAN HIGH module (ECM)
0.75
R

4 H-6 37 E-57 18 E-57

1E-178 Electronic control fuel injection system (Common rail type)

Vehicle
speed sensor A
(*: Specifications vary depending on each machine. Refer to the machine’s manual.)

Meter
Machine
control
unit
Engine CAN HIGH CAN LOW
coolant
temperature
gauge

Machine trouble
diagnosis monitor
CKP sensor, vehicle speed sensor, fuel temperature sensor, engine coolant temperature sensor, engine oil

TSHK0017
 Engine control
module (ECM)
5V Boost pressure
sensor signal
5V

Boost temperature
sensor signal

74 E-56 109 E-56 91 E-56 95 E-56

15 H-20 17 H-20 16 H-20 8 H-20

Boost temperature sensor, boost pressure sensor circuit

0.75 0.75 0.75 0.75 0.75

B/R R/L R/L L R/W

2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

Boost temperature sensor

Boost pressure sensor

TSWG0034
Electronic control fuel injection system (Common rail type) 1E-179
 CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V Engine control
module (ECM)

B+ B+ B+

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

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

CMP sensor, common rail pressure sensor, EGR circuit

0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B

1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W
1E-180 Electronic control fuel injection system (Common rail type)

1 E-112 2 E-112 3 E-112 1 E-113 2 E-113 3 E-113 W

V U

EGR position sensor/EGR motor

EGR valve

CMP sensor Common rail pressure sensor

TSHK0018
 A A

Engine control
Accelerator Accelerator module (ECM)
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V

Vcc

37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Machine
control unit

CAN HIGH CAN LOW

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

6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor
Accelerator position sensor, barometric pressure sensor, intake air temperature sensor circuit

TSHK0019
Electronic control fuel injection system (Common rail type) 1E-181
 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-182 Electronic control fuel injection system (Common rail type)
Idling selector switch, idle up switch, idle down switch, mode map switch circuit

29 E-57 30 E-57 31 E-57 25 E-57 34 E-57 48 E-57

Engine control
module (ECM)
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

Idling selector Idle up Idle down Mode map Mode map Mode map
switch signal switch signal switch signal switch 0 signal switch 1 signal switch 2 signal

TSWG0037
 Electronic control fuel injection system (Common rail type) 1E-183
Memory clear switch, engine stop switch circuit
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

(15A)*
Key switch (ON)
Engine control module (ECM)

control unit
Machine
E-57

CAN HIGH CAN LOW

CAN HIGH

18
E-57
CAN LOW

37

Engine stop switch

A

E-57
47

Memory clear switch

A

E-57
32

B
B

TSWG0038
1E-184 Electronic control fuel injection system (Common rail type)
Engine harness location
4HK1

:Engine harness

13 12 11 10
7 6

9
1

2
8

3 4

TSHK0020

Name
1. Engine coolant temperature sensor 8. SCV
2. Overheating switch 9. Fuel temperature sensor
3. Common rail pressure sensor 10. Boost temperature sensor
4. Engine oil pressure sensor 11. Boost pressure sensor
5. CKP sensor 12. Injector
6. CMP sensor 13. Glow plug
7. EGR position sensor
 98003-428 SENSOR:BOOST PRESS
E80 E75
EGR VALVE 1 2 3
E113 0.75 0.75 0.75
R/L L R/W
SENSOR:COMMON RAIL 1 2 3 4
0.75 0.75 0.75 0.75
L G/Y G/W G /B
5 6 7 8
1 2 3
0.5 0. 5 0.5 0.75 0.75 0.75 0.75
L/W Br L L/W W/L W/B W/R
H94
1 2 3 4 INJECTOR
1.25 1.25 1.25 1.25
W R R W
5 6 7 8
0.75 0.75 0.75 0.75 E163
L L /R L /Y L / W
SENSOR:MAT(BOOST TEMP)
1 2
0.75 0.75
R / L B /R

1 1 2 3
5 0.75 0.5 0.5
B/W B /W V /W Y

GLOW PLUG(No.1) SENSOR:CAM ANGLE(G)

E112
H1

E161
1 2
1 2 SCV
0.75 0.75 1 2
0.75 0.75 R /W R /B
B/Y R /B 0 .5 0 .5
1 Y V /W
3 0.75
0.75 G SENSOR:NE.CRANK
R

SENSOR:WATER SWITCH:O/H E93 E98

SENSOR:FUEL TEMP
E90 E164 1 2
0.75 0.75
B /Y Y /G

1 2 3
0.75 0.75 0.75
B / Y L / Y W/ B

SENSOR:OIL PRESSRE
E76

1
5
B/W

H22

1 2 3 4
0.5 0.5 0.75 0.5
Y V/W B Y
5 6 7 8
0.5 0.75 0.75 0.75
V/W B/W R /B R /W
4 3 2 1 9 10 11 12
1.25 1.25 0.75 0.75 0.75 0.5
W R W/B L /Y B /Y L
3 2 1 4 3 2 1 8 7 6 5
0.75 0.75 0.75 0.75 0.75 0.75 13 14 15 16
Y/G R/W R/B G / Y G /W G /B 0.75 0.75 0.75 0.75
L L / R L/ Y L / W 0.5 0.5 0.75 0.75
6 5 4 8 7 6 5 Br L/W B/R L
12 11 10 9
0.75 0.75 0.75 0.75 0.75 17 18 19 20
G R W /L W /B W/R 0.75
R/L
H6 H8 H12 H20

TSHK0034
Electronic control fuel injection system (Common rail type) 1E-185
1E-186 Electronic control fuel injection system (Common rail type)
E75 E98

Terminal Terminal
Number Number
1 Boost pressure sensor GND 1 CKP +
2 Boost pressure sensor Vout 2 CKP GND
3 Boost pressure sensor Vcc
E112
E76 Terminal
Number
Terminal
Number 1 CMP shield
1 Engine oil pressure sensor GND 2 CMP GND
2 Engine oil pressure sensor Vout 3 CMP +
3 Engine oil pressure sensor Vcc
E113
E80 Terminal
Number
Terminal
Number 1 Common rail pressure sensor GND
1 EGR Vcc 2 Common rail pressure sensor Vout
2 EGR hall sensor W 3 Common rail pressure sensor Vcc
3 EGR hall sensor V
E161
4 EGR hall sensor U
5 EGR GND Terminal
Number
6 EGR motor W
1 SCV — Hi
7 EGR motor V
2 SCV — Lo
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 E164

Terminal
E93
Number
Terminal 1 Overheating switch
Number
1 Fuel temperature sensor GND H1
2 Fuel temperature sensor + Terminal
Number
1 Glow
 Electronic control fuel injection system (Common rail type) 1E-187
H6 H20

Terminal Terminal
Number Number
1 SCV−Lo 1 CKP +
2 SCV−Hi 2 CKP GND
3 Fuel temperature sensor + 3 CKP shield
4 ECT meter 4 CMP +
5 — 5 CMP GND
6 Overheating switch 6 CMP shield
7 ECT +
H8
8 Boost pressure sensor Vcc
Terminal 9 Engine oil pressure sensor Vcc
Number
10 Engine oil pressure sensor Vout
1 EGR hall sensor U
11 Engine oil pressure sensor GND
2 EGR hall sensor V
12 Common rail pressure sensor Vcc
3 EGR hall sensor W
13 Common rail pressure sensor Vout
4 —
14 Common rail pressure sensor GND
5 EGR motor U
15 Boost temperature sensor +
6 EGR motor V
16 Boost pressure sensor Vout
7 EGR motor W
17 Boost pressure sensor GND
8 —
18 —
H12 19 —

Terminal 20 —
Number
H22
1 —
2 — Terminal
Number
3 Injector power supply 2
1 Glow
4 Injector power supply 1
5 OS — INJ3 signal/Injector #4 H94
6 OS — INJ2 signal/Injector #3
Terminal
7 OS — INJ4 signal/Injector #2 Number
8 OS — INJ1 signal/Injector #1 1 Injector power supply 1
9 — 2 Injector power supply 2
10 — 3 Injector power supply 2
11 — 4 Injector power supply 1
12 — 5 OS — INJ1 signal/Injector #1
6 OS — INJ4 signal/Injector #2
7 OS — INJ2 signal/Injector #3
8 OS — INJ3 signal/Injector #4
1E-188 Electronic control fuel injection system (Common rail type)
Cylinder head

E27 E31 E35 E37

H94 H94
(Male connector (Female connector on injector side)
on ECM side)

TSHK0044
Electronic control fuel injection system (Common rail type) 1E-189
1E-190 Electronic control fuel injection system (Common rail type)
6HK1

:Engine harness

13 12 11 10
7 6

2
8

3 4

TSHK0021

Name
1. Engine coolant temperature sensor 8. SCV
2. Overheating switch 9. Fuel temperature sensor
3. Common rail pressure sensor 10. Boost temperature sensor
4. Engine oil pressure sensor 11. Boost pressure sensor
5. CKP sensor 12. Injector
6. CMP sensor 13. Glow plug
7. EGR position sensor
 98013-710
1 2 3 4
0.75 1.25 1.25
G/B R R
5 6 7 8
0.75 0.75
L/R L/Y

H95
INJECTOR 2(#4.5.6 )
H94
INJECTOR 1(#1.2.3 )
1 2 3 4
0.75 1.25 1.25
L W W
5 6 7 8
1
5 0.75 0.75
B/W L/W G/R 1 2 3 4
0.75 0.75 0.75 0.75
L G /Y G/W G /B
H1 5 6 7 8
0.75 0.75 0.75 0.75
GLOW PLUG L/W W/L W/B W/R

E80

1 2
EGR VALVE
0.75 0.75
B/Y R / B
3 1 2 3
0.75 0.75 0.75 0.75
R R/L L R/W E93
1 2
0.75 0.75 SENSOR:FUEL TEMP
E90 B /Y Y /G
E75
SENSOR:WATER 1 2
SENSOR:BOOST PRESS 0.75 0.75
R /L B /R

E163
SENSOR:MAT(BOOST TEMP) 1 2
E164 0.75 0.75
R/W R/B
SWITCH:O/H
1
0.75 E161
G
SCV

1 2 3
0.5 0.5 0 .5
L/W Br L
1 2 3
0 . 7 5 0 .5 0 .5
E113 B /W V /W Y

SENSOR:COMMON RAIL E112

SENSOR:CAM ANGLE(G)

1 2
1 2 3 0 .5 0 .5
0.75 0.75 0.75 E76 Y V /W
B / Y L / Y W/ B

E98
SENSOR:OIL PRESSRE
SENSOR:NE.CRANK

1 2 3 4
0.5 0.5 0.75 0.5
Y V/W B Y
5 6 7 8
0.5 0.75 0.75 0.75
V/W B/W R/B R/W
4 3 2 1 9 10 11 12
1.25 1.25 0.75 0.75 0.75 0.5
W R W/B L/ Y B/Y L
3 2 1 4 3 2 1 8 7 6 5 13 14 15 16
0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.5 0.5 0.75 0.75
Y/G R /W R/B G /Y G/W G /B L L / R L/ Y L / W Br L/W B/R L 1
6 5 4 8 7 6 5 12 11 10 9 17 18 19 20 5
0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 B/W
G R W /L W /B W/R G/R G/B R/L

H6 H8 H12 H20 H22

TSHK0035
Electronic control fuel injection system (Common rail type) 1E-191
1E-192 Electronic control fuel injection system (Common rail type)
E75 E98

Terminal Terminal
Number Number
1 Boost pressure sensor GND 1 CKP +
2 Boost pressure sensor Vout 2 CKP GND
3 Boost pressure sensor Vcc
E112
E76 Terminal
Number
Terminal
Number 1 CMP shield
1 Engine oil pressure sensor GND 2 CMP GND
2 Engine oil pressure sensor Vout 3 CMP +
3 Engine oil pressure sensor Vcc
E113
E80 Terminal
Number
Terminal
Number 1 Common rail pressure sensor GND
1 EGR Vcc 2 Common rail pressure sensor Vout
2 EGR hall sensor W 3 Common rail pressure sensor Vcc
3 EGR hall sensor V
E161
4 EGR hall sensor U
5 EGR GND Terminal
Number
6 EGR motor W
1 SCV — Hi
7 EGR motor V
2 SCV — Lo
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 E164

Terminal
E93
Number
Terminal 1 Overheating switch
Number
1 Fuel temperature sensor GND H1
2 Fuel temperature sensor + Terminal
Number
1 Glow
 Electronic control fuel injection system (Common rail type) 1E-193
H6 H20

Terminal Terminal
Number Number
1 SCV−Lo 1 CKP +
2 SCV−Hi 2 CKP GND
3 Fuel temperature sensor + 3 CKP shield
4 ECT meter 4 CMP +
5 — 5 CMP GND
6 Overheating switch 6 CMP shield
7 ECT +
H8
8 Boost pressure sensor Vcc
Terminal 9 Engine oil pressure sensor Vcc
Number
10 Engine oil pressure sensor Vout
1 EGR hall sensor U
11 Engine oil pressure sensor GND
2 EGR hall sensor V
12 Common rail pressure sensor Vcc
3 EGR hall sensor W
13 Common rail pressure sensor Vout
4 —
14 Common rail pressure sensor GND
5 EGR motor U
15 Boost temperature sensor +
6 EGR motor V
16 Boost pressure sensor Vout
7 EGR motor W
17 Boost pressure sensor GND
8 —
18 —
H12 19 —

Terminal 20 —
Number
H22
1 —
2 — Terminal
Number
3 Injector power supply 2
1 Glow
4 Injector power supply 1
5 OS — INJ3 signal/Injector #3 H94
6 OS — INJ2 signal/Injector #5
Terminal
7 OS — INJ4 signal/Injector #6 Number
8 OS — INJ1 signal/Injector #1 1 —
9 — 2 OS — INJ1 signal/Injector #1
10 — 3 Injector power supply 1
11 OS — INJ6 signal/Injector #4 4 Injector power supply 2
12 OS — INJ5 signal/Injector #2 5 —
6 OS−INJ3 signal/Injector #3
7 OS−INJ5 signal/Injector #2
8 —
1E-194 Electronic control fuel injection system (Common rail type)
H95

Terminal
Number
1 —
2 OS−INJ6 signal/Injector #4
3 Injector power supply 2
4 Injector power supply 1
5 —
6 OS−INJ4 signal/Injector #6
7 OS−INJ2 signal/Injector #5
8 —

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
 Electronic control fuel injection system (Common rail type) 1E-195
H94/H95 connector

Name
1. Engine harness-side connector
2. Cylinder head outside connector
3. Cylinder head inside connector
4. Injector harness-side connector
1E-196 Electronic control fuel injection system (Common rail type)
Connector list
No. Connector Face No. Connector Face
E-75

Engine
E-27 harness
1 2 3
side
(male 003-501
#1 injector (Silver) terminal) (Black)
E-76

Engine
E-29 harness 1 2 3
side
(male 003-501

#2 injector (Silver) terminal) (Black)

E-80

Engine
E-31 harness
side
(male
#3 injector (Silver) terminal) (Black)
E-90

Engine 1 2
E-33 harness
3
side
(male 003-500
#4 injector (Silver) terminal) (Light gray)
E-93

Engine
E-35 harness
side
(male
#5 injector (Silver) terminal) (Green)
E-98

Engine
E-37 harness
side
(male
#6 injector (Silver) terminal) (Dark gray)
E-56 E-112

Machine Engine
harness harness
side side
(female (male
terminal) (Black) terminal) (Black)
E-57 E-113

Machine Engine
harness harness
side side
(female (male
terminal) (Black) terminal) (Black)
 Electronic control fuel injection system (Common rail type) 1E-197

No. Connector Face No. Connector Face

E-114 H-6

Engine Engine
harness harness
side side
(male (male
terminal) (Black) terminal) (Black)
E-161 H-6

Engine Machine
harness harness
side side
(male (female
terminal) (Light gray) terminal)

E-163 H-8

Engine Engine
harness harness
side side
(male (male
terminal) (Gray) terminal) (Black)
H-8

Machine
E-164 harness
side
000-009 (female
(Silver) terminal)

FB-124 H-12

Engine Engine
harness harness
side side
(male (male
terminal) (Black) terminal) (Black)
FL-150 H-12

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

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

H-20
4 3 2 1
8 7 6 5
Engine
12 11 10 9
H1 harness- 16 15 14 13
side 20 19 18 17
000-009 (female 020-501
(Silver) terminal) (Light gray)
1E-198 Electronic control fuel injection system (Common rail type)

No. Connector Face No. Connector Face

H22 H-95

Engine Cylinder
harness- head
side inside
(female (female
terminal) (Light gray) terminal) (Dark gray)
H22 H-95

Machine Injector
harness harness
side side
(male (male
terminal) terminal)

H-94

Engine
harness
side
(male
terminal) (Dark gray)
H-94

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

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

Injector
harness
side
(male
terminal)

H-95

Engine
harness
side
(male
terminal) (Gray)
H-95

Cylinder
head
outside
(female
terminal) (Dark gray)
 Electronic control fuel injection system (Common rail type) 1E-199

List of function checks

Interview Inspection to comprehend the trouble symptom and diagnose properly based on a
customer’s complaint.
OBD system check Inspection to identify defective point of engine control system (inspection
procedure)
Diagnosis lamp illumination Inspection when diagnosis lamp does not come on when starter switch is turned
circuit system check ON.
Diagnosis lamp blinking circuit Inspection when diagnosis lamp does not blink (remains on) when diagnostic
system check switch is turned ON.
Scan tool power supply circuit Inspection when scan tool (Tech2) does not operate.
system check
Scan tool communication Inspection when scan tool (Tech2) cannot communicate with ECM.
circuit 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.
1E-200 Electronic control fuel injection system (Common rail type)
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 • If there is no complaint for operationality, never
malfunction. It is the first procedure of all complaint perform this diagnostic step unless otherwise
diagnosis for operationality. Use of this diagnostic step instructed in other items.
properly enables to shorten the diagnosis period and to • Before the diagnosis, check the service
prevent unnecessary replacement of proper parts. information.
• Never erase DTCs unless otherwise instructed
Test description
in the diagnostic step.
2. 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
and scan tool. manual “Engine section”.
4. If DTC is detected, proceed to the relevant DTC
• Ensure the battery is fully charged.
diagnosis by referring to the list of DTC. If more than
one DTC is detected, start with the one with smallest • Make sure the battery cable is normal and
DTC number unless otherwise instructed in the securely connected.
diagnostic step. • Make sure the ground cable of ECM is
connected to the proper position securely.

Step Action Value YES NO

1. Turn the key switch to “ON”.
2. Check the diagnosis lamp (trouble display
monitor on the machine). Go to Step 2 in
1 — “Diagnosis lamp
Does the diagnosis lamp (trouble display illumination circuit
monitor on the machine) come on? Go to Step 2. system check”.
1. Connect the diagnosis connector.
• If the machine is not equipped with
diagnosis lamp, go to Step 3. Go to Step 2 in
2 —
2. Check the diagnosis lamp. “Diagnosis lamp
blinking circuit
Does the diagnosis lamp blink? Go to Step 3. system check”.
Is the scan tool (KW communication)
3 —
available? Go to Step 4. Go to Step 6.
1. Connect the scan tool.
2. Turn the key switch to “ON”.
Go to “Scan tool
4 3. Turn the power switch of the scan tool to —
power supply
“ON”.
circuit system
Does the scan tool powered “ON”? Go to Step 5. check”.
Communicate with ECM using scan tool. Go to Step 2 in
“Scan tool
5 Does it communicate with ECM properly? — communication
circuit system
Go to Step 6. check”.
Turn the key switch to “START”. Go to “Starting
6 — circuit system
Does the starter operate?
Go to Step 7. check”.
Turn the key switch to “START”.
7 — Go to “Starting
Does the engine start? Go to Step 8. system check”.
Check if DTC is detected.
8 — Go to the relevant
Is DTC detected? DTC diagnosis. Go to Step 9.
 Electronic control fuel injection system (Common rail type) 1E-201

Step Action Value YES NO

1. Check for following troubles.
• Engine stall
• Engine hunting, rough idling
• Engine output lowering, blow up fault,
engine breathing
• Exhaust gas contains a lot of white
9 smoke. —
• Exhaust gas contains a lot of black
smoke.
• Idling rotation cannot be adjusted.
• Idling rotation cannot be reduced. Go to the relevant
trouble symptom
Is the trouble detected? diagnosis. Normal system
1E-202 Electronic control fuel injection system (Common rail type)
Diagnosis lamp illumination circuit system check
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

(15A)*

A A

Meter
Tachometer
Boost
Diagnosis Engine oil QOS indicator Charge
Machine trouble temperature O/H lamp
lamp pressure lamp lamp lamp
diagnosis monitor lamp

3 H-6

1 E-164

Machine
control unit O/H switch

CAN LOW CAN HIGH

Generator

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

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

Tachometer signal
CAN HIGH CAN LOW

TSHK0022

Description of circuit Following inspections are necessary to detect these

The power supply voltage is supplied to the diagnosis causes.
lamp via key switch, and the signal from ECM will turn • Improper connection of harness connector and
the lamp on. The ECM turns the diagnosis lamp on ECM connector
during lamp check with the key switch “ON” and when – Poor connection of terminal from connector
DTC is detected. Also when the diagnosis connector is – Unmatched terminals are fitted.
connected, it blinks the diagnosis lamp according to the – Damage of connector lock
DTC detected. A monitor circuit is provided inside the
– Poor contact between terminal and wire
ECM to monitor the lamp operation.
• Damaged harness
Diagnostic aid – Visually check the harness for damage.
If the intermittent trouble is suspected, followings may – Check the relevant items on the scan tool data
be the cause. display while moving the connector and the
harness which are related to the sensor. The
• Improper connection of harness connector
variation of the display indicates the faulty part.
• Defective harness routing
• Worn harness cladding
• Wire disconnection inside harness cladding
 Electronic control fuel injection system (Common rail type) 1E-203

Step Action Value YES NO

1. Turn the key switch to “ON”.
1 2. Check the diagnosis lamp. — Go to “Diagnostic
Does the diagnosis lamp come on? aid”. Go to Step 2.
Remove the diagnosis lamp to check its
2 condition. — Replace the
Is the trouble detected? diagnosis lamp. Go to Step 3.
Check for open/short circuit between the
diagnosis lamp and ECM and power supply
3 circuit using DMM. —
Repair the
Is the trouble detected? harness. Go to Step 4.
4 Is EMPS available? — Go to Step 5. Go to Step 6.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
5 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR. Check the repair,
and Go to “OBD
Is the procedure completed? system check”. —
Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
6 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR. Check the repair,
and Go to “OBD
Is the procedure completed? system check”. —
1E-204 Electronic control fuel injection system (Common rail type)
Diagnosis lamp blinking circuit system check

Engine control
module (ECM)
CAN LOW CAN HIGH

KWP2000

52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57

1 FL-150 7 FL-150

DLC Machine
control unit

5 FL-150 4 FL-150

CAN HIGH CAN LOW

TSHK0023

Description of circuit Following inspections are necessary to detect these

The power supply voltage is supplied to the diagnosis causes.
lamp via key switch, and the signal from ECM will turn • Improper connection of harness connector and
the lamp on. The ECM turns the diagnosis lamp on ECM connector
during lamp check with the key switch “ON” and when – Poor connection of terminal from connector
DTC is detected. Also when the diagnosis connector is – Unmatched terminals are fitted.
connected, it blinks the diagnosis lamp according to the – Damage of connector lock
DTC detected. A monitor circuit is provided inside the
– Poor contact between terminal and wire
ECM to monitor the lamp operation.
• Damaged harness
Diagnostic aid – Visually check the harness for damage.
If the intermittent trouble is suspected, followings may – Check the relevant items on the scan tool data
be the cause. display while moving the connector and the
harness which are related to the sensor. The
• Improper connection of harness connector
variation of the display indicates the faulty part.
• Defective harness routing
• Worn harness cladding
• Wire disconnection inside harness cladding
 Electronic control fuel injection system (Common rail type) 1E-205

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Connect the DMM between the diagnosis
connector (male-side) and the ground.
1 3. Turn the key switch to “ON”. 0V

Is the DMM indication more than the specified

value? Go to Step 2. Go to Step 3.
Check for installation condition of the ECM
connector and coupling connector.
1. Check for play or looseness in the
2 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Verify repair. Go to Step 3.
1. Check for followings in the circuit between
ECM and diagnosis connector using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
3 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Verify repair. Go to Step 4.
1. Check for following in the circuit between
diagnosis connector and ground.
• Open circuit
4 • High resistance —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Verify repair. Go to Step 5.
Check the diagnosis lamp blinking condition
again.
1. Turn the key switch to “ON”.
5 2. Connect the diagnosis connector. —
3. Check the diagnosis lamp.
Go to “Diagnostic
Does the diagnosis lamp blink? aid”. Go to Step 6.
6 Is EMPS available? — Go to Step 7. Go to Step 8.
1E-206 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

7 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Verify repair. Go to Step 8.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Verify repair. —

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM
 Electronic control fuel injection system (Common rail type) 1E-207

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
3 Open circuit/ Resistance • Key switch “OFF” 52 - Diagnosis 100Ω or 10 MΩ or
high measurement connector terminal less more
resistance
Short circuit to Resistance • Key switch “OFF” 52 - Ground 10 MΩ or 100Ω or
ground measurement more less

Scan tool power supply circuit system check

TSWG0162

Name
1. Battery cable 2. Power socket cable (AC/DC adapter)

Circuit description Following inspections are necessary to detect these

The ECM and other ECUs communicate with the scan causes.
tool via data link connector (DLC). Power supply • Improper connection of harness connector and
voltage for the scan tool is provided from the battery. ECM connector
– Poor connection of terminal from connector
Caution: – Unmatched terminals are fitted.
Use a 12-V battery from the chassis ground side for
– Damage of connector lock
the power supply to the scan tool.
– Poor contact between terminal and wire
Diagnostic aid • Damaged harness
If the intermittent trouble is suspected, followings may – Visually check the harness for damage.
be the cause. – Check the relevant items on the scan tool data
• Improper connection of harness connector display while moving the connector and the
harness which are related to the sensor. The
• Defective harness routing
variation of the display indicates the faulty part.
• Worn harness cladding
• Wire disconnection inside harness cladding Test description
Important:
Before starting this diagnostic step, check if the
scan tool operates properly on other machine.
1E-208 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the voltage of battery on the machine
1 using DMM. 10V Charge or replace
Is the voltage more than specified value? Go to Step 2. the battery.
Check for poor contact in the scan tool-side
2 cable. —
Is the trouble detected? Go to Step 3. Go to Step 4.
Correct the connection of the scan tool.
3 —
Is the procedure completed? Go to Step 4. —
Check for open/short circuit in the cable Request for repair
between scan tool and battery. by referring to the
4 —
operation manual
Is the trouble detected? of the scan tool. Go to Step 5.
1. Connect the scan tool to the machine.
2. Turn the power switch of the scan tool to
5 “ON”. — Check the repair,
and Go to “OBD
Does the scan tool powered “ON”? system check”. Go to Step 1.
 Electronic control fuel injection system (Common rail type) 1E-209
Scan tool communication circuit system check

Engine control
module (ECM)
CAN LOW CAN HIGH

KWP2000

52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57

1 FL-150 7 FL-150

DLC Machine
control unit

5 FL-150 4 FL-150

CAN HIGH CAN LOW

TSHK0023

Circuit description Following inspections are necessary to detect these

The engine control module (ECM) performs KW causes.
communication with the scan tool via 16-pin data link • Improper connection of harness connector and
connector (DLC). ECM connector
– Poor connection of terminal from connector
Diagnostic aid – Unmatched terminals are fitted.
If the intermittent trouble is suspected, followings may – Damage of connector lock
be the cause. – Poor contact between terminal and wire
• Improper connection of harness connector • Damaged harness
• Defective harness routing – Visually check the harness for damage.
• Worn harness cladding – Check the relevant items on the scan tool data
• Wire disconnection inside harness cladding display while moving the connector and the
harness which are related to the sensor. The
variation of the display indicates the faulty part.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1E-210 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check for installation condition of the ECM
connector and coupling connector.
1. Check for play or looseness in the
2 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 9. Go to Step 3.
1. Check the DLC for following conditions.
• Poor connection of terminal from
connector
3 • Poor contact between terminal and wire —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 9. Go to Step 4.
1. Check for followings in the circuit between
ECM and DLC using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
4 —
• Open circuit
• High resistance
• Short circuit to ground
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 9. Go to Step 5.
1. Connect the scan tool.
2. Turn the key switch to “ON”.
5 3. Communicate with ECM using scan tool. —
Go to “Diagnostic
Does it communicate with ECM properly? aid”. Go to Step 6.
6 Is EMPS available? — Go to Step 7. Go to Step 8.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
7 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 9. Go to Step 8.

 Electronic control fuel injection system (Common rail type) 1E-211

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 9. —

1. Connect the scan tool.
2. Turn the key switch to “ON”.
9 3. Communicate with ECM using scan tool. —

Does it communicate with ECM properly? Verify repair. Go to Step 2.

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
4 Open circuit/ Resistance • Key switch “OFF” 38 - DLC terminal 100Ω or 10 MΩ or
high measurement No. 7 less more
resistance
Short circuit to Resistance • Key switch “OFF” 38 - Ground 10 MΩ or 100Ω or
ground measurement more less
1E-212 Electronic control fuel injection system (Common rail type)
Starting circuit system check
Starter ECM control
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

(100A)*

Starter
B

C
Battery
B

Generator

(15A)*
(60A)*

Glow relay Sterter relay

Starter cut relay Main relay

(10A)*
1 H-22

5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START

10 E-57 Key switch 14 E-57

Engine
control
Glow Glow relay control module
plug (ECM)

Starter cut relay signal

TSHK0024
 Electronic control fuel injection system (Common rail type) 1E-213
Starter safety relay control
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

Starter
B

Battery B
Generator

(100A)* L

(15A)* (60A)*

B C
Safty relay

L S

Glow relay

A A
1 H-22
B Br C B ACC Br C
5 (ON) (ST) (ON) (ST)
B/W
OFF OFF
ON ON
START START
1 H-1
Key switch
10 E-57

Engine
control
module (ECM)
Glow relay control
Glow
plug

TSHK0026

Circuit description – Damage of connector lock

ECM turns the starter relay “ON” when the key switch is – Poor contact between terminal and wire
turned to “START” position. When the starter relay is • Damaged harness
“ON”, the starter operates to start the engine. – Visually check the harness for damage.
– Check the relevant items on the scan tool data
Diagnostic aid display while moving the connector and the
If the intermittent trouble is suspected, followings may harness which are related to the sensor. The
be the cause. variation of the display indicates the faulty part.
• Improper connection of harness connector
• Defective harness routing Test description
• Worn harness cladding Numbers below indicate step numbers in the diagnostic
• Wire disconnection inside harness cladding chart.
Following inspections are necessary to detect these 4. If these DTCs are detected, engine may not start.
causes. 5. When the ECM does not recognize the “START”
position signal from the key switch, the starter cut relay
• Improper connection of harness connector and
is set “OFF”. Therefore, the starter relay will not turn
ECM connector
“ON”.
– Poor connection of terminal from connector
– Unmatched terminals are fitted.
1E-214 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

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

Is the “Starter switch (ST)” displayed “ON”? Go to Step 6. Go to Step 5.

1. Check for followings in the circuit between
key switch and ECM using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
5 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 12.
1. Turn the key switch to “OFF”.
2. Remove the starter cut relay.
6 3. Check for continuity between the starter —
cut relay switch-side terminals.
Is the trouble detected? Go to Step 7. Go to Step 8.
Replace the starter cut relay.
7 —
Is the procedure completed? Go to Step 13. —
1. Turn the key switch to “OFF”.
2. Remove the starter relay.
3. Connect the battery to the starter relay
8 coil-side terminal. —
4. Check for continuity between the starter
relay switch-side terminals.
Is the trouble detected? Go to Step 9. Go to Step 10.
Replace the starter relay.
9 —
Is the procedure completed? Go to Step 13. —
Turn the key switch to “START”.
10 — Go to “Diagnostic
Does the starter operate? aid”. Go to Step 11.
 Electronic control fuel injection system (Common rail type) 1E-215

Step Action Value YES NO

1. Check the following circuits for open circuit
or high resistance.
• Between key switch and starter cut
relay
• Between starter cut relay and starter
11 relay —
• Between starter relay and ground
• Between starter relay and starter
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 16. Go to Step 12.
1. Inspect by referring to “Electrical system”
in the service manual “Engine section”
12 2. If the trouble is detected, repair as —
required.
Is the trouble detected? Go to Step 16. Go to Step 13.
13 Is EMPS available? — Go to Step 14. Go to Step 15.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
14 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 16. Go to Step 15.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
15 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 16. —

Turn the key switch to “START”. Check the repair,
16 — and Go to “OBD
Does the starter operate?
system check”. Go to Step 1.
1E-216 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for followings in the circuit between
key switch and ECM using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
17 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 18.
1. Turn the key switch to “OFF”.
2. Remove the starter cut relay.
18 3. Check for continuity between the starter —
cut relay switch-side terminals.
Is the trouble detected? Go to Step 19. Go to Step 20.
Replace the starter cut relay.
19 —
Is the procedure completed? Go to Step 13. —
1. Turn the key switch to “OFF”.
2. Remove the starter relay.
3. Connect the battery to the starter relay
20 coil-side terminal. —
4. Check for continuity between the starter
relay switch-side terminals.
Is the trouble detected? Go to Step 9. Go to Step 10.

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
 Electronic control fuel injection system (Common rail type) 1E-217

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
5, 17 Open circuit/ Resistance • Key switch “OFF” 46 - Key switch 100Ω or 10 MΩ or
high measurement “START” terminal less more
resistance
Short circuit to Resistance • Key switch “OFF” 46 - Ground 10 MΩ or 100Ω or
ground measurement more less
6, 18 Open circuit/ Resistance • Key switch “OFF” Starter cut relay 100Ω or 10 MΩ or
high measurement • Relay alone Switch-side terminal less more
resistance
8, 20 Open circuit/ Resistance • Key switch “OFF” Starter relay 100Ω or 10 MΩ or
high measurement • Relay alone Switch-side terminal less more
resistance • Relay “ON”
1E-218 Electronic control fuel injection system (Common rail type)
Starting system check

2 E-161

SCV

1 E-161

0.75 0.75
R/B R/W

1 H-6 2 H-6

97 E-56 89 E-56 105 E-56 113 E-56

Engine control
module(ECM)

B+

TSHK0027

About starting system check Diagnostic aid

Starting system check is systematic method to detect If there is relevant DTC to CKP sensor and CMP
the cause of that engine does not start. Followings are sensor, the engine will not start until memory clear is
the preconditions for performing this diagnosis. performed.
• Battery is fully charged, and battery cable is If the intermittent trouble is suspected, followings may
securely connected. be the cause.
• Engine speed at cranking is normal. • Improper connection of harness connector
• Sufficient amount of fuel is supplied. • Defective harness routing
• No air mixed in the fuel. • Worn harness cladding
• Air cleaner element and fuel filter is normal. • Wire disconnection inside harness cladding
• Correct fuel is used. Following inspections are necessary to detect these
causes.
Important: • Improper connection of harness connector and
Start with the DTC diagnosis relevant to fuel system ECM connector
if there is any. – Poor connection of terminal from connector
– Unmatched terminals are fitted.
– Damage of connector lock
– Poor contact between terminal and wire
 Electronic control fuel injection system (Common rail type) 1E-219
Test description
Numbers below indicate step numbers in the chart.
4. If the SCV-LOW circuit is shorted to ground, the SCV
drive current will not be more than 900mA.
5. If the engine starts with the SCV connector
disconnected, SCV system may be faulty. Also, if the
engine does not start, the fuel system may be faulty.
6. Check the signal and operation of each sensor and
injector.

Step Action Value YES NO

Is the emergency stop switch equipped? Turn the switch to
1 — “OFF”, and Go to
Step 2. Go to Step 2.
1. Turn the key switch to “ON”.
2. Crank the engine for 15 seconds.
2 3. Check the DTC. — Go to the relevant
diagnosis of DTC
Is DTC detected? detected. Go to Step 3.
Is the scan tool (KW communication)
3 —
available? Go to Step 4. Go to Step 11.
While cranking the engine, check for “SCV F/
B” on the data display using scan tool.
4 900mA
Is the “SCV F/B” more than the specified
value? Go to Step 5. Go to Step 6.
1. Disconnect the SCV connector.
5 2. Crank the engine. — Go to DTC P0090. Go to “Fuel system
Does the engine start? check”.
Repair the SCV-LOW circuit between the ECM
6 and the SCV. —
Is the procedure completed? Go to Step 8. —
1. Check the relevant items to the following
using scan tool to see if the values are
normal. (Refer to “Tech2 data reference
value” for specified value.)
• Engine coolant temperature (ECT)
sensor
7 • Common rail pressure sensor —
• EGR position sensor
• Injector
2. If the trouble is detected, replace the
circuit or sensor as required.
Is the trouble detected? Go to Step 9. Go to Step 8.
1. Check for following faults.
• Engine mechanical timing is off.
• Improper installation position of
flywheel
8 • Excessive clogging in intake system —
• Excessive clogging in exhaust system
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 9. —
1E-220 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
9 —
2. Turn the key switch to “OFF” for more than
10 seconds.
3. Start the engine.
Is the trouble detected? Go to Step 10. Go to Step 3.
Check the DTC. Go to the relevant Check the repair,
10 — diagnosis of DTC and Go to “OBD
Is DTC detected?
detected. system check”.
1. Repair the SCV-LOW circuit between the
ECM and the SCV.
11 2. If the trouble is detected, repair the circuit —
as required.
Is the procedure completed? Go to Step 12. —
1. Check for following faults.
• Engine mechanical timing is off.
• Improper installation position of
flywheel
12 • Excessive clogging in intake system —
• Excessive clogging in exhaust system
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 9. —
 Electronic control fuel injection system (Common rail type) 1E-221
Fuel system check

2 4HK1

3
1

6
7

5 6HK1

TSHK0041

Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter

About fuel system • Worn harness cladding

Fuel system consists of the fuel tank, fuel filter, supply • Wire disconnection inside harness cladding
pump, common rail, and injector each of which is Following inspections are necessary to detect these
connected by the fuel pipe. causes.
• Improper connection of harness connector and
Diagnostic aid ECM connector
Followings are considered as the major possible cause – Poor connection of terminal from connector
of the fault in fuel system. – Unmatched terminals are fitted.
• Air mixed in the fuel system. – Damage of connector lock
• Clogged fuel filter – Poor contact between terminal and wire
• Damage, clogging, improper connection of fuel
pipe
• Fuel tank fault
• Supply pump fault
• Injector fault
• Pressure limiter fault
If the intermittent trouble is suspected, followings may
be the cause.
• Improper connection of harness connector
• Defective harness routing
1E-222 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the fuel quality.
1. Drain fuel from the fuel tank.
2. Add proper fuel.
1 3. Bleed air from the fuel. —
4. Start the engine.
Does the engine start? Go to Step 6. Go to Step 2.
Check the fuel quantity.
2 — Supply fuel, and
Is sufficient amount of fuel supplied? Go to Step 3. Go to Step 3.
Check if there are additional filters or parts,
other than genuine fuel filter, pre-filter and
3 electromagnetic pump, in the machine’s fuel —
pipe.
Are there any additional filters or parts? Go to Step 4. Go to Step 5.
1. Remove the additional filter and bleed air.
• If the fuel resistance is increased, the
4 DTC P1093 or P1094 may be detected. —
2. Start the engine.
Does the engine start? Go to Step 6. Go to Step 5.
1. Check for excessive dirt or clogging in the
(main and pre-) fuel filters.
2. Check for excessive dirt or clogging in the
electromagnetic pump filter.
5 3. If the trouble is detected, clean or replace. —
4. If air is entered in the main filter, examine
the cause and repair.
Is the procedure completed? Go to Step 6. —
1. Check for damage, clogging, or improper
connection in the fuel pipe.
6 2. If the trouble is detected, repair as —
required.
Is the procedure completed? Go to Step 7. —
1. Check for following troubles in the fuel
tank.
• Foreign matter mixed in the fuel
• Disconnection or damage in fuel supply
pipe
• Crush or damage in tank
7 • Wrong assembly of fuel pipe —
• Clogging at filler neck
• Water mixed in fuel
2. If the trouble is detected, repair as
required.
Is the procedure completed? Go to Step 8. —
Bleed air from the fuel.

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

Is the procedure completed? Verify repair. —

 Electronic control fuel injection system (Common rail type) 1E-223
Intake system check
About intake system
(If intake system parts are installed by the machine
manufacturer, refer to the machine’s manual.)
The intake system consists of the air cleaner, intake
pipe, turbocharger, etc. Intake air is supplied to the
engine through the air cleaner and intake manifold.

Step Action Value YES NO

Check for excessive dirt or clogging in the air
1 cleaner. —
Is the trouble detected? Go to Step 2. Go to Step 3.
Clean or replace the air cleaner.
2 —
Is the procedure completed? Go to Step 3. —
1. Check for crush, breakage, or air leakage
in the intake pipe.
2. Make sure that the intake pipe is a
genuine part.
3 • Check for bend or improper piping that —
may cause increasing in intake air
resistance.
3. Check the reed valve for breakage.
Is the trouble detected? Go to Step 4. Go to Step 5.
Repair or replace the intake pipe or reed valve.
4 —
Is the procedure completed? Go to Step 5. —
Check the turbocharger.
• Check for abnormal rattling in the
turbine shaft.
• Check for oil leakage.
5 —
Note:
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? Go to Step 6. Go to Step 7.

Repair or replace the turbocharger.

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

Is the procedure completed? Go to Step 7. —

Repair the machine.
7 —
Is the procedure completed? Verify repair. —
1E-224 Electronic control fuel injection system (Common rail type)
Reed valve check If the reed valve is broken, bypass of intake air
deteriorates air-fuel ratio (A/F), resulting in output
lowering.
Check the reed valve for deformation or breakage.

TSWG0168

Name
1. Reed valve
2. EGR valve
3. Exhaust side
4. Intake side

Exhaust system check

About exhaust system

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

Step Action Value YES NO

Check for crush, breakage, or exhaust leakage
1 in the exhaust pipe and tail pipe. —
Is the trouble detected? Go to Step 2. Go to Step 3.
Repair or replace the exhaust pipe or tail pipe.
2 —
Is the procedure completed? Go to Step 3. —
Repair the machine.
3 —
Is the procedure completed? Verify repair. —
 Electronic control fuel injection system (Common rail type) 1E-225
EGR control system check

Engine control
module (ECM)

CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V

B+ B+ B+

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

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

0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B

1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W

1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 W

V U

EGR position sensor/EGR motor

EGR valve

CMP sensor Common rail pressure sensor

TSHK0028

Circuit description
The ECM operates the EGR valve based on engine
speed, engine coolant temperature, intake air
temperature, fuel injection amount, and barometric
pressure. The EGR motor drives the EGR valve, and
the EGR position sensor detects the EGR valve
opening angle.

Step Action Value YES NO

1. Turn the key switch to “ON”.
Go to the relevant
1 2. Check the DTC. — diagnosis of DTC
Is DTC detected? detected. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 8.
1E-226 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Start the engine.
2. Warm-up the engine until the engine
coolant temperature is 70°C (158°F).
3 3. Check the value for “EGR position” using ±3%
scan tool.
Is “EGR position” within the specified value? Normal system Go to Step 4.
1. Perform “EGR control test” using scan
tool.
4 2. Press the “Up” “Down” soft key. ±3%
3. Check the value for “EGR position”.
Is “EGR position” within the specified value? Go to Step 6. Go to Step 5.
Replace the EGR valve.
After replacing the EGR valve or ECM, the
EGR valve position learning must be
performed in the following procedure.
1. Turn the key switch to “ON”.
5 2. Turn the key switch to “OFF”. —
3. Leave as it is for 10 seconds.
Failure to perform above procedure may result
in detection of DTC for EGR.
Is the procedure completed? Go to Step 6. —
1. Check for damage or gas leakage in the
EGR pipe.
6 2. If the trouble is detected, repair as —
required.
Is the procedure completed? Go to Step 7. —
1. Start the engine.
2. Warm-up the engine until the engine
coolant temperature is 70°C (158°F).
7 3. Check the value for “EGR position” using ±3%
scan tool.
Is “EGR position” within the specified value? Verify repair. Go to Step 3.
1. Remove the EGR valve.
2. Check the EGR valve for anchoring,
clogging, etc.
8 3. If the trouble is detected, repair as —
required.
Is the trouble detected? Go to Step 9. Normal system
Replace the EGR valve.
After replacing the EGR valve or ECM, the
EGR valve position learning must be
performed in the following procedure.
1. Turn the key switch to “ON”.
9 2. Turn the key switch to “OFF”. —
3. Leave as it is for 10 seconds.
Failure to perform above procedure may result
in detection of DTC for EGR.
Is the procedure completed? Go to Step 10. —
 Electronic control fuel injection system (Common rail type) 1E-227

Step Action Value YES NO

1. Check for damage or gas leakage in the
EGR pipe.
10 2. If the trouble is detected, repair as —
required.
Is the procedure completed? Go to Step 11. —
1. Turn the key switch to “ON”.
Go to the relevant
11 2. Check the DTC. — diagnosis of DTC
Is DTC detected? detected. Go to Step 2.

EGR valve check

TSWG0150

Push the EGR valve with finger to make sure it opens/

closes smoothly. Also, make sure that the valve closes
completely when the finger is released.

EGR hysteresis

ON

OFF

60
(140 F)
TSWG0206
1E-228 Electronic control fuel injection system (Common rail type)
QOS system check
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

(100A)*

Starter
B

C
Battery
B

Generator

(15A)*
(60A)*

Glow relay Sterter relay

Starter cut relay Main relay

(10A)*
1 H-22

5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START

10 E-57 Key switch 14 E-57

Engine
control
Glow Glow relay control module
plug (ECM)

Starter cut relay signal

TSHK0024
 Electronic control fuel injection system (Common rail type) 1E-229

(15A)*

A A

Meter
Tachometer
Boost
Diagnosis Engine oil QOS indicator Charge
Machine trouble temperature O/H lamp
lamp pressure lamp lamp lamp
diagnosis monitor lamp

3 H-6

1 E-164

Machine
control unit O/H switch

CAN LOW CAN HIGH

Generator

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

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

Tachometer signal
CAN HIGH CAN LOW

TSHK0022

Note: Test description

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

Step Action Value YES NO

Perform the OBD check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1E-230 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “ON”.
2. Check the DTC.
2 Is relevant DTC to the engine coolant — Go to the relevant
temperature sensor, QOS indicator lamp, or diagnosis of DTC
glow reply detected? detected. Go to Step 3.
Check the fuse.
Check for blown out fuse relevant to the QOS
3 — If the fault still
system.
remains after
Is the trouble detected? repair, go to step 4. Go to Step 7.
Check for short circuit between the fuse, ECM,
glow plug, and QOS indicator lamp.
1. Disconnect the harness from the fuse,
glow relay, ECM, glow plug, and QOS
indicator lamp. 10 MΩ or
4
2. Measure the resistance between each more
glow relay terminal, each QOS indicator
lamp terminal, and the ground.
Is the resistance specified value? Go to Step 6. Go to Step 5.
Repair the short circuit between the fuse, ECM,
5 glow plug, and QOS indicator lamp. —
Is the procedure completed? — Go to Step 6.
1. Replace the fuse.
2. Turn the key switch to “ON”.
6 3. Make sure that the fuse is not blown. —

Is the procedure completed? — Go to Step 7.

1. Turn the key switch to “OFF”.
2. Turn the key switch to “ON”.
7 3. Check the QOS indicator lamp. —

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.
Is the trouble detected? Go to Step 9. Go to Step 10.
1. Replace the QOS indicator lamp.
2. Turn the key switch to “ON”.
9 3. Check the QOS indicator lamp. —

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

Is the resistance specified value? Go to Step 7. Go to Step 11.

Repair the QOS indicator lamp terminal-to-
11 ECM harness. —
Is the procedure completed? Go to Step 7. —
 Electronic control fuel injection system (Common rail type) 1E-231

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Turn the key switch to “ON”.
12 3. Check the QOS indicator lamp. —
Does the QOS indicator lamp go OFF within 10
seconds? Go to Step 14. Go to Step 13.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary. If rewriting is not necessary, go
to step 3.
13 3. Replace the ECM. —
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.
Is the procedure completed? Go to Step 14. —
1. Perform “Glow plug relay” test using scan
tool.
When the scan tool is not available,
14 remove the relay and test it by itself. —
2. Press the “ON” and “OFF” softkeys.
Does the glow relay display (contact) “ON” and
“OFF”? Go to Step 15. Go to Step 13.
1. Turn the key switch to “OFF”.
2. Remove all the glow plugs. 6Ω
15 3. Measure the resistance between each (Normal
glow plug terminal and the ground. temperature)
Is the resistance specified value? Go to Step 16. Go to Step 20.
1. Turn the glow relay “ON” using the “Glow
plug relay” test of the scan tool.
When the scan tool is not available,
remove the glow relay and short between
the terminals.
16 2. Measure the voltage between each 18V
cylinder glow plug harness terminal and
the ground using DMM.
Are the voltages at all the cylinders more than
specified value? Go to Step 17. Go to Step 18.
1. Turn the glow relay “OFF” using the “Glow
plug test” of the scan tool.
When the scan tool is not available,
remove the glow relay.
17 2. Measure the voltage between each 0V
cylinder glow plug harness terminal and
the ground using DMM.
Are the voltages at all the cylinders specified
value? Normal system Go to Step 19.
Repair the open circuit between the glow relay
and the glow plug, or the short circuit to the
18 ground circuit. —

Is the procedure completed? Go to Step 21. —

1E-232 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

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

Is the procedure completed? Go to Step 21. —

Replace the glow plug.
20 —
Is the procedure completed? Go to Step 21. —
1. Turn the glow relay “ON” using the “Glow
plug test” of the scan tool.
When the scan tool is not available,
remove the glow relay and short between
the terminals.
21 2. Measure the voltage between each 18V
cylinder glow plug harness terminal and
the ground using DMM.
Are the voltages at all the cylinders more than
specified value? Go to Step 22. Go to Step 16.
1. Turn the glow relay “OFF” using the “Glow
plug test” of the scan tool.
When the scan tool is not available,
remove the glow relay.
22 2. Measure the voltage between each 0V
cylinder glow plug harness terminal and
the ground using DMM.
Are the voltages at all the cylinders specified
value? Verify repair. Go to Step 17.
 Electronic control fuel injection system (Common rail type) 1E-233

List of diagnostic trouble code

List of diagnostic trouble codes
On some machines, the diagnosis lamp comes on instead of trouble display monitor on the machine.
4HK1
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0087 227 No pump Common rail 900 rpm or more Actual rail Approx. 3 Intense engine ON *1
pressure pressure pressure is 15 sec. vibration, rough
feed (fuel does not Mpa (2,176 psi) idling, output
leakage) increase to or less. lowering, blow up
the required fault, black smoke
area. emitted, and
excessive output
are possible.
Back-up:
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0088 118 Common rail Common rail • Key switch input Rail pressure is Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or more than 185 sec. vibration, rough
fault abnormal more. MPa (26832 idling, output
(1st stage) increase • DTC P0088, psi). lowering, blow up
P0192, P0193, or fault, black smoke
P1635 is not emitted, and
detected. excessive output
• Actual rail are possible.
pressure is 2 MPa Back-up:
(290 psi) or more, Limited injection
and 70 rpm or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
Common rail Common rail • Key switch input Common rail Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or pressure fault sec. vibration, rough
fault abnormal more. (1st stage) is idling, output
(2nd stage) increase • DTC P0088, completed, and lowering, blow up
P0192, P0193, or rail pressure is fault, black smoke
P1635 is not more than 190 emitted, and
detected. MPa (27557 excessive output
• Actual rail psi). are possible.
pressure is 2 MPa Back-up:
(290 psi) or more, Limited injection
and 70 rpm or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
1E-234 Electronic control fuel injection system (Common rail type)

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0089 151 Common rail Common rail • Key switch input Actual rail Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or pressure is 40 sec. vibration, rough
fault abnormal more. MPa (5802 psi) idling, output
(Excessive increase • DTC P0089, or more higher lowering, blow up
pressure P0192, P0193, or than target rail fault, black smoke
feed in P1635 is not pressure. emitted, and
pump) detected. excessive output
• Coolant are possible.
temperature is Back-up:
60°C (140°F) or Limited injection
more, and 375 rpm amount 3 (multi-
or more. injection stopped)
• Duty to SCV is Target RP upper
40% or more, or limit (80 MPa
SCV target {11603 psi})
pressure feed is 90
mm3/sec
(0.0055cu⋅in/sec)
or less.
P0090 247 SCV drive Open/short • Main relay power When SCV drive Approx. 2 Engine stall and/or ON *2
system open circuit of supply voltage is current exceeds sec. engine blow up are
circuit, +B SCV/ 18V or more. specified value possible depending
short or harness • DTC P1630 is not for 2 seconds or on the condition of
ground short detected. more, or when open/short circuit.
• SCV drive duty is difference Black smoke
between 10 — between target emitted, excessive
90%. and actual output
current exceeds Back-up:
specified value Limited injection
for 2 seconds or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0107 71 Barometric Open/short • Key switch input Barometric Approx. 5 Due to back-up ON *2
pressure circuit/ voltage is 18V or pressure sensor sec. equivalent to 2500
sensor fault deterioration more. voltage is lower m (8200 ft)
(low voltage of sensor or • DTC P1630 or than 0.5 V. • Black smoke
fault) harness P1632 is not emitted at high
detected. altitude
• Output shortage at
low altitude
Back-up:
Barometric
pressure default
setting (80 kPa
{11.6 psi})
EGR stopped
P0108 Barometric Short circuit • Key switch input Barometric Approx. 4 Due to back-up ON *2
pressure in sensor or voltage is 18V or pressure sensor sec. equivalent to 2500
sensor fault harness more. voltage is more m (8200 ft)
(high voltage • DTC P1630 or than 3.8 V. • Black smoke
fault) P1632 is not emitted at high
detected. altitude
• Output shortage at
low altitude
Back-up:
Barometric
pressure default
setting (80 kPa
{11.6 psi})
EGR stopped
 Electronic control fuel injection system (Common rail type) 1E-235

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0112 22 Intake air Short circuit • Key switch input Intake air Approx. 4 Not in particular ON *2
temperature in sensor or voltage is 18V or temperature sec. Back-up:
sensor fault harness more. sensor voltage is Intake air
(low voltage • DTC P1630 or less than 0.1 V. temperature default
fault) P1632 is not setting
detected. (at starting: −10°C
{14°F}, at running:
25°C {77°F})
EGR stopped
P0113 Intake air Open/short • Key switch input Intake air Approx. 4 Not in particular ON *2
temperature circuit/ voltage is 18V or temperature sec. Back-up:
sensor fault deterioration more. sensor voltage is Intake air
(high voltage of sensor or • DTC P1630 or more than 4.95 temperature default
fault) harness P1632 is not V. setting
detected. (at starting: −10°C
• 3 minutes or more {14°F}, at running:
has elapsed after 25°C {77°F})
starting engine. EGR stopped
P0117 23 Engine Short circuit • Key switch input Engine coolant Approx. 4 Start ability ON *2
coolant in sensor or voltage is 18V or temperature sec. deteriorates at low
temperature harness more. sensor voltage is temperatures or
sensor fault • DTC P1630 or less than 0.1 V. black smoke
(low voltage P1633 is not emission is
fault) detected. possible, output
lowering depending
on conditions.
Back-up:
Coolant
temperature default
setting
(at starting: −20°C
{−4°F}, at running:
80°C {176°F})
EGR stopped
P0118 Engine Open/short • Key switch input Engine coolant Approx. 4 At normal ON *2
coolant circuit/ voltage is 18V or temperature sec. temperature: Black
temperature breakage of more. sensor voltage is smoke emission,
sensor fault sensor or • DTC P1630 or more than 4.85 greater engine
(high voltage harness P1633 is not V. combustion noise
fault) detected. possible.
• 3 minutes or more During idling at low
has elapsed after atmospheric
starting engine. temperatures:
Rough idling,
engine stall, white
smoke emission
possible.
Back-up:
Coolant
temperature default
setting
(at starting: −20°C
{−4°F}, at running:
80°C {176°F})
EGR stopped
1E-236 Electronic control fuel injection system (Common rail type)

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0182 211 Fuel Short circuit • Key switch input Combustion Approx. 4 Operationality is ON *2
temperature in sensor or voltage is 18V or temperature sec. affected.
sensor fault harness more. sensor voltage is Back-up:
(low voltage • DTC P1630 or less than 0.1 V. Fuel temperature
fault) P1633 is not default setting
detected. (at starting: −20°C
{−4°F}, at running:
70°C {158°F)
P0183 Fuel Open/short • Key switch input Combustion Approx. 4 Not in particular ON *2
temperature circuit/ voltage is 18V or temperature sec. Back-up:
sensor fault breakage of more. sensor voltage is Fuel temperature
(high voltage sensor or • DTC P1630 or more than 4.85 default setting
fault) harness P1633 is not V. (at starting: −20°C
detected. {−4°F}, at running:
• 3 minutes or more 70°C {158°F})
has elapsed after
starting engine.
P0192 245 Common rail Short circuit • Key switch input Common rail Nearly Engine blow up ON *2
pressure in sensor or voltage is 18V or pressure sensor simultaneo Back-up:
sensor fault harness more. voltage is less us to fault Specified back-up
(low voltage • DTC P1630 or than 0.7 V. occurrence value (depending
fault) P1635 is not on the machine
detected. manufacturer)
P0193 Common rail Open/short • Key switch input Common rail Nearly Engine stall ON *2
pressure circuit/ voltage is 18V or pressure sensor simultaneo possible
sensor fault breakage of more. voltage is more us to fault Output lowering
(high voltage sensor or • DTC P1630 or than 4.5 V. occurrence Back-up:
fault) harness P1635 is not Specified back-up
detected. value (depending
on the machine
manufacturer)
P0201 271 Open circuit Open/short • Main relay power No injector 1 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #1 electrical 18V or more. signal exists. idling, output
drive system wiring No. 1 • 70 rpm or more lowering, blow up
cylinder • DTC P0611, fault
injector P1262, or P0201 is Back-up:
not detected. Injection for cylinder
#1 stopped, EGR
stopped
P0202 272 Open circuit Open/short • Main relay power No injector 2 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #2 electrical 18V or more. signal exists. idling, output
drive system wiring No. 2 • 70 rpm or more lowering, blow up
cylinder • DTC P0611, fault
injector P1261 or P0202 is Back-up:
not detected. Injection for cylinder
#2 stopped, EGR
stopped
P0203 273 Open circuit Open/short • Main relay power No injector 3 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #3 electrical 18V or more. signal exists. idling, output
drive system wiring No. 3 • 70 rpm or more lowering, blow up
cylinder • DTC P0611, fault
injector P1261 or P0203 is Back-up:
not detected. Injection for cylinder
#3 stopped, EGR
stopped
 Electronic control fuel injection system (Common rail type) 1E-237

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0204 274 Open circuit Open/short • Main relay power No injector 4 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #4 electrical 18V or more. signal exists. idling, output
drive system wiring No. 4 • 70 rpm or more lowering, blow up
cylinder • DTC P0612, fault
injector P1262 or P0204 is Back-up:
not detected. Injection for cylinder
#4 stopped, EGR
stopped
P0219 543 Overrun Engine • Key switch input When the engine Approx. 1 Output lowering ON *2
speed voltage is 18V or speed exceeds sec. Back-up:
abnormally more. setting value Limited injection
high (depending on amount 1
the machine Limitation is lifted if
manufacturer) the speed
decreases
P0237 32 Boost Open/short • Key switch input Boost pressure Approx. 3 Operationality is ON *2
pressure circuit/ voltage is 18V or sensor voltage is sec. affected.
sensor fault breakage of more. less than 0.1V. Back-up:
(low voltage sensor or • DTC P1630 or Specified back-up
fault) harness P1634 is not value (depending
detected. on the machine
manufacturer)
P0238 Boost Short circuit • Key switch input Boost pressure Approx. 3 Black smoke ON *2
pressure in sensor or voltage is 18V or sensor voltage is sec. emitted
sensor fault harness more. more than 4.9V. Back-up:
(high voltage • DTC P1630 or Specified back-up
fault) P1634 is not value (depending
detected. on the machine
manufacturer)
P0335 15 Crank Open circuit • CMP sensor Cam signal When • Output lowering, ON *1
sensor fault in sensor/ pulse is normal. exists but no trouble white smoke
(no signal) wiring • DTC P0335, crank signal. occurs 14 emission, intense
P0336, P0340, out of 21 engine vibration
P0341 or P1345 is samples. possible
not detected. • Engine stall
• Engine is running. possible (restart is
possible when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
P0336 Crank Broken • CMP sensor Number of pulse When • Output lowering, ON *1
sensor fault teeth/ pulse is normal. for crank signal trouble white smoke
(signal fault) unnecessary • DTC P0335, is mismatched. occurs 14 emission, intense
signal mixed P0336, P0340, out of 21 engine vibration
(such as P0341 or P1345 is samples. possible
short circuit not detected. • Engine stall
with other • Engine is running. possible (restart is
wiring) possible when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
1E-238 Electronic control fuel injection system (Common rail type)

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0340 14 Cam sensor Open circuit • Key switch input Crank signal When • Behavior does not ON *1
fault (no in sensor/ voltage is 18V or exists but no trouble change during
signal) wiring more. cam signal. occurs 7 engine running.
• Crank pulse is out of 8 • After engine stalls,
normal. samples. engine will not start.
• DTC P0335, Back-up:
P0336, P0340, Engine running
P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
• Engine is running. Unable to identify
cylinder (unable to
restart)
P0341 Cam sensor Broken • Key switch input Number of pulse When • Behavior does not ON *1
fault (signal teeth/ voltage is 18V or for cam signal is trouble change during
fault) unnecessary more. mismatched. occurs 7 engine running.
signal mixed • Crank pulse is out of 8 • After engine stalls,
(such as normal. samples. engine will not start.
short circuit • DTC P0335, Back-up:
with other P0336, P0340, Engine running
wiring) P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
• Engine is running. Unable to identify
cylinder (unable to
restart)
P0380 66 Glow relay Open/short • Key switch input No glow relay When Operationality is not ON *1
fault circuit/ power supply monitor signal trouble affected.
damage of voltage is higher exists against occurs 25 Back-up:
relay or than 16 V but lower glow relay drive out of 30 Back-up: No back-
harness than 32 V. indication. samples. up action
P0381 67 Glow lamp Open/short • Key switch input Glow lamp drive When Operationality is not ON
fault circuit/ voltage is 18 V or indication signal trouble affected.
damage of more. is unmatched occurs 25 Back-up:
lamp or • DTC P0381 is not with glow lamp out of 30 Back-up: No back-
harness detected. monitor signal. samples. up action
P0487 44 EGR Open/short • Main relay input EGR position Approx. 3 Operationality is not ON *1
position fault circuit/ voltage is 18V or output signal is sec. affected.
(Brushless damage of more. abnormal. Back-up:
specification sensor • DTC P1630 or Instruction to fully
) harness P1635 is not close EGR valve
detected.
P0488 45 EGR valve Trouble/ • DTC P1630, Difference Approx. 10 Operationality is not ON *2
control fault open circuit P1635, P0487, between target sec. affected.
or valve P0488, or P1635 is valve lift and Back-up:
engage/ not detected. actual position is Instruction to fully
stuck in • Main relay voltage more than 20%. close EGR valve
drive motor is between 20 —
side 32 V.
• Difference
between target
EGR opening
angle and actual
one is 20% or less.
P0522 294 Engine oil Open/short • Key switch input Engine oil Approx. 4 Operationality is not ON *1
pressure circuit/ voltage is 18V or pressure sensor sec. affected.
sensor fault breakage of more. voltage is less Back-up:
(low voltage sensor or • DTC P1633 is not than 0.1V. Back-up: No back-
fault) harness detected. up action
P0523 Engine oil Short circuit • Key switch input Engine oil Approx. 4 Operationality is not ON *2
pressure in sensor or voltage is 18V or pressure sensor sec. affected.
sensor fault harness more. voltage is more Back-up:
(high voltage • DTC P1633 is not than 4.85V. Back-up: No back-
fault) detected. up action
 Electronic control fuel injection system (Common rail type) 1E-239

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0601 53 ROM fault ROM fault ROM is faulty. Engine stopped ON *2
— Reflash failure — Back-up:
Engine stopped
P0603 54 EEPROM EEPROM EEPROM is Operationality is not ON *2
fault fault faulty. affected.
— — Back-up:
Back-up: No back-
up action
P0606 51 CPU fault CPU fault Sub-CPU Nearly Output lowering ON *2
detects main simultaneo Back-up:
CPU fault in 100 us to fault Limited injection
msec after key occurrence amount 2 (multi-
switch ON. injection stopped)
(SUB-CPU SUB-CPU stops
resets CPU.) CPU.
—
Sub-CPU Nearly Unable to start ON Diagnosed
detects main simultaneo Back-up: for
CPU fault in 100 us to fault Limited injection 100msec
msec after key occurrence amount 2 (multi- only after
switch ON. injection stopped) KEY-ON.
(SUB-CPU SUB-CPU stops
resets CPU.) CPU.
52 CPU Sub-CPU • 480 msec or more RUN-SUB pulse Nearly Output lowering ON *2
monitoring fault has elapsed after does not change simultaneo Back-up:
IC fault key switch ON. for 20 msec or us to fault Limited injection
• Key switch input more. occurrence amount 1
power supply
voltage is higher
than 16 V.
P0611 34 Charge ECU charge • Main relay power When charge Approx. Intensive engine ON *2
circuit fault circuit 1 fault supply voltage is circuit bank 1 1.5 sec. vibration, rough
(bank 1) (internal 18V or more. voltage inside idling, output
burnout, ECU is low. lowering, blow up
open circuit, fault, engine stall
etc.) are possible.
Back-up:
Common 1 stop
(#1, #4 cylinders
stopped), EGR
stopped
P0612 Charge ECU charge When charge Approx. Intensive engine ON
circuit fault circuit 2 fault circuit bank 2 1.5 sec. vibration, rough
(bank 2) (internal voltage inside idling, output
burnout, ECU is low. lowering, blow up
open circuit, fault, engine stall
etc.) are possible.
Back-up:
Common 2 stop
(#2, #3 cylinders
stopped), EGR
stopped
P0650 77 Check Lamp fault • Key switch input No check engine Approx. Operationality is not Does *2
engine lamp voltage is 18V or lamp monitor 1.5 sec. affected. not
fault more. signal exists. Back-up: come
• DTC P0650 is not Back-up: No back- on.
detected. up action
1E-240 Electronic control fuel injection system (Common rail type)

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1093 227 No pump Fuel leakage • Key switch input Actual rail Approx. 5 Intense engine ON *1
pressure (large voltage is 18V or pressure is 30 sec. vibration, rough
feed (fuel amount) more. MPa (4351 psi) idling, output
leakage) • 1200 rpm or more or more lower lowering, blow up
• Duty to SCV is than target rail fault, black smoke
33% or less, or pressure. emitted, engine
pressure feed is stall, and excessive
28000mm 3/sec output are possible.
(1.7cu⋅in/sec) or Back-up:
more. Limited injection
• DTC P0192, amount 3 (multi-
P0193, P1093, injection stopped)
P0090, P1291, Target RP upper
P1292, or P1635 is limit (80 MPa
not detected. {11603 psi})
P1095 225 Pressure Pressure • Key switch input Pressure limiter Approx. 1 Output lowering, ON *1
limiter open limiter is voltage is 18V or is opened. sec. hunting
opened. more. Back-up:
• DTC P1095, Limited injection
P0192, P0193, amount 1
P1630, or P1635 is
not detected.
• 50 rpm or more
P1112 295 Boost Open/short • Key switch input Boost Approx. 4 Operationality is not ON *2
temperature circuit/ voltage is 18V or temperature sec. affected.
sensor fault breakage of more. sensor voltage is Back-up:
(low voltage sensor or • DTC P1634 is not less than 0.1 V. Back-up: No back-
fault) harness detected. up action
P1113 Boost Short circuit • Key switch input Boost Approx. 4 Operationality is not ON *2
temperature in sensor or voltage is 18V or temperature sec. affected.
sensor fault harness more. sensor voltage is Back-up:
(high voltage • Coolant more than Back-up: No back-
fault) temperature is 4.95V. up action
50°C (122°F) or
more.
• 3 (or 5) minutes
have passed after
engine starting
(depending on the
machine
manufacturer)
• DTC P1634 is not
detected.
P1173 542 Overheat Overheat • Key switch input • Coolant Approx. 5 Operationality is not Does *2
condition voltage is 18V or temperature is sec. affected. not
more. more than Back-up: come
• DTC P1630, 120°C (248°F). Back-up: No back- on.
P1633, P0117, or up action
P0118 is not
detected.
• Under operation
P1261 158 Injection Open/short • Main relay power No injector 1 and Approx. 3 Intensive engine ON *1
nozzle circuit in supply voltage is 4 monitor input sec. vibration, rough
common 1 injector 18V or more. signal exists. idling, output
drive system common 1- • 70 rpm or more lowering, blow up
fault side • None of the fault
electrical following DTC sets Engine stall is
wiring, EDU are detected; DTC possible.
output part P0611, P1261 and Back-up:
fault P0201; DTC Common 1 stop
P0611, P1261 and (#1, #4 cylinders
P0202; DTC stopped), EGR
P0611, P1261 and stopped
P0203.
 Electronic control fuel injection system (Common rail type) 1E-241

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1262 159 Injection Open/short • Main relay power No injector 2 and Approx. 3 Intensive engine ON *1
nozzle circuit in supply voltage is 3 monitor input sec. vibration, rough
common 2 injector 18V or more. signal exists. idling, output
drive system common 2- • 70 rpm or more lowering, blow up
fault side • None of the fault
electrical following DTC sets Engine stall is
wiring, EDU are detected; DTC possible.
output part P0612, P1262 and Back-up:
fault P0204; DTC Common 2 stop
P0612, P1262 and (#2, #3 cylinders
P0205; DTC stopped), EGR
P0612, P1262 and stopped
P0206.
P1271 24 Accelerator Difference in • Key switch input Difference in Approx. 3 1 system fault...No Does *1
sensor 1-2 opening voltage is 18V or opening angle sec. back-up not
comparison angle more. between 2 system come
fault between • DTC P1630, accelerator fault...Accelerator on.
accelerator P1631, P1271, sensors 1 and 2 opening angle is
sensors 1-2 P1277, P1278, is 45% or more. controlled to 0%.
is 45% or P1282, or P1283 is Back-up:
more. not detected. 1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1277 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 1 circuit/ voltage is 18V or sensor 1 voltage sec. back-up not
fault (low breakage of more. is lower than 0.2 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1277, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1278 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 1 circuit/ voltage is 18V or sensor 1 voltage sec. back-up not
fault (high breakage of more. is more than 4.9 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1278, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1282 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 2 circuit/ voltage is 18V or sensor 2 voltage sec. back-up not
fault (low breakage of more. is lower than 0.2 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1282, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
1E-242 Electronic control fuel injection system (Common rail type)

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1283 24 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 2 circuit/ voltage is 18V or sensor 2 voltage sec. back-up not
fault (high breakage of more. is more than 4.9 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1283, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1345 16 Cam sensor Camshaft • Key switch input Correct cam When • Behavior does not ON *1
out of phase gear/ voltage is 18V or pulse does not trouble change during
crankshaft more. exist in crank occurs 7 engine running.
gear • DTC P0335, gap position. out of 8 • After engine stalls,
installing P0336, P0340, samples. engine will not start.
angle is out P0341, P1345, or Back-up:
of phase, or P1635 is not Specified back-up
damage in detected. value (depending
gear. • CMP sensor on the machine
pulse is normal. manufacturer)
• Crank pulse is
normal.
P1625 416 Main relay Open/ • Key switch input Main relay Approx. 2 Engine does not ON *2
system fault ground short voltage is 18V or system voltage sec. start.
(Not enter) circuit in more. is 1V or less with Back-up:
harness, • DTC P1630 is not main relay coil Back-up: No back-
relay OFF detected. output ON. up action
anchoring • 3 seconds or
more has elapsed
after key switch
ON.
• Main relay drive
indication ON
Harness +B • DTC P1625 or Relay does not Approx. 5 Vehicle power ON *1
short, relay P0606 is not cut off despite of sec. supply cannot be
ON detected. main relay coil shut off.
anchoring output OFF Back-up:
indication. Back-up: No back-
up action
P1630 36 A/D A/D A/D conversion Immediatel Output lowering, ON *2
conversion conversion failure y Black smoke
fault fault emitted
Back-up:
Analog sensor
system default
— processing
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
 Electronic control fuel injection system (Common rail type) 1E-243

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1631 55 Voltage fault Power • DTC P1630 is not Key switch Approx. Accelerator opening ON *2
in 5-V power supply detected. power supply 0.5 sec. angle is controlled
supply 1 wiring short • Key switch input voltage is 5.5V to 0%.
to sensor, or power supply or more, or 4.5V Back-up:
breakage in voltage is between or less, when Same to accelerator
element/ 16 — 32 V. battery voltage is sensor fault
circuit for between 16V —
power 32V.
supply
P1632 Voltage fault • DTC P1630 is not Key switch Approx. Due to back-up ON *2
regulation
in 5-V power detected. power supply 0.5 sec. equivalent to 2500
inside ECM.
supply 2 • Key switch input voltage is 5.5V m (8200 ft)
power supply or more, or 4.5V • Black smoke
voltage is between or less, when emitted at high
16 — 32 V. battery voltage is altitude
between 16V — • Output shortage at
32V. low altitude
Back-up:
Same to barometric
pressure and intake
air temperature
sensor fault
P1633 Voltage fault • DTC P1630 is not Key switch Approx. Startability ON *2
in 5-V power detected. power supply 0.5 sec. deteriorates at low
supply 3 • Key switch input voltage is 5.5V temperatures or
power supply or more, or 4.5V black smoke
voltage is between or less, when emission is
16 — 32 V. battery voltage is possible, output
between 16V — lowering or
32V. operationality is
affected depending
on conditions.
Back-up:
Same to coolant
temperature, fuel
temperature, and oil
pressure sensor
fault
P1634 Voltage fault • DTC P1630 is not Key switch Approx. Operationality is ON *2
in 5-V power detected. power supply 0.5 sec. affected.
supply 4 • Key switch input voltage is 5.5V Back-up:
power supply or more, or 4.5V Same to boost
voltage is between or less, when pressure and boost
16 — 32 V. battery voltage is temperature sensor
between 16V — fault
32V.
P1635 Voltage fault • DTC P1630 is not Key switch Approx. Engine blow up, ON *2
in 5-V power detected. power supply 0.5 sec. output lowering,
supply 5 • Key switch input voltage is 5.5V black smoke
power supply or more, or 4.5V emission, engine
voltage is between or less, when stall are possible.
16 — 32 V. battery voltage is Back-up:
between 16V — Same to rail
32V. pressure sensor
fault and EGR
position sensor fault
U2104 84 CAN Bus CAN • Key switch input Bus-off is At 3 sec. Set to idle speed. ON *3
fault communicati voltage is 12V or detected. continuous Back-up:
on fault more. ly Running at 1500
rpm.
U2106 85 CAN timeout CAN • DTC U2104 is not CAN data At 1 sec. Set to idle speed. ON *3
fault communicati detected. reception does continuous Back-up:
on fault • Key switch input not complete at ly Specified back-up
voltage is 12V or a set time. value (depending
more. on the machine
manufacturer)
1E-244 Electronic control fuel injection system (Common rail type)
About recovery from failure *2
There are three modes for recovery from failure. When the DTC has recovered to normal condition in the
To clear the trouble displayed on the monitor of the ignition cycle that the DTC is detected, the diagnosis
machine, one more ignition cycle may be needed after lamp and back up mode will also be recovered.
the following ignition cycle.
1 2

*1
Key ON
Even if the DTC has restored normally, the diagnosis switch
lamp and back-up mode are not restored in the ignition and
Engine
cycle that the DTC is detected. After turning the key run OFF

switch OFF, DTC diagnosis is performed when the

vehicle starts again. If it is judged as normal, everything
will be recovered to normal from the next ignition cycle. ON
Diag
lamp
1 2 3
OFF

Key ON
switch
and
Engine ON
run OFF
Back-up
mode
OFF

ON
TSWG0166
Diag
lamp
OFF
Name
1. DTC is detected.
2. Recovery to normal.

ON
Back-up
mode
*3
OFF
When the DTC has recovered to normal in the ignition
cycle that the DTC is detected, the back-up mode will
TSWG0165 be recovered normally, but the diagnosis lamp does not
go off.
Name
1. DTC is detected. 1 2
2. Repair and inspection
3. Returned to normal. Key ON
switch
and
Enigne
run OFF

ON
Diag
lamp
OFF

ON
Back-up
mode
OFF

TSWG0207

Name
1. DTC is detected.
2. Recovery to normal.
 Electronic control fuel injection system (Common rail type) 1E-245
6HK1
Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0087 227 No pump Common rail 900 rpm or more Actual rail Approx. 3 Intense engine ON *1
pressure pressure pressure is 15 sec. vibration, rough
feed (fuel does not MPa (2176 psi) idling, output
leakage) increase to or less at 900 lowering, blow up
the required rpm or more. fault, black smoke
area. emitted, and
excessive output
are possible.
Back-up:
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0088 118 Common rail Common rail • Key switch input Rail pressure is Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or more than 185 sec. vibration, rough
fault abnormal more. MPa (26832 idling, output
(1st stage) increase • DTC P0088, psi). lowering, blow up
P0192, P0193, or fault, black smoke
P1635 is not emitted, and
detected. excessive output
• Actual rail are possible.
pressure is 2 MPa Back-up:
(290 psi) or more, Limited injection
and 70 rpm or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
Common rail Common rail • Key switch input Common rail Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or pressure fault sec. vibration, rough
fault abnormal more. (1st stage) is idling, output
(2nd stage) increase • DTC P0088, completed, and lowering, blow up
P0192, P0193, or rail pressure is fault, black smoke
P1635 is not more than 190 emitted, and
detected. MPa (27557 excessive output
• Actual rail psi). are possible.
pressure is 2 MPa Back-up:
(290 psi) or more, Limited injection
and 70 rpm or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0089 151 Common rail Common rail • Key switch input Actual rail Approx. 5 Intense engine ON *1
pressure pressure voltage is 18V or pressure is 40 sec. vibration, rough
fault abnormal more. MPa (5802 psi) idling, output
(Excessive increase • DTC P0089, or more higher lowering, blow up
pressure P0192, P0193, or than target rail fault, black smoke
feed in P1635 is not pressure. emitted, and
pump) detected. excessive output
• Coolant are possible.
temperature is Back-up:
60°C (140°F) or Limited injection
more, and 375 rpm amount 3 (multi-
or more. injection stopped)
• Duty to SCV is Target RP upper
40% or more, or limit (80 MPa
SCV target {11603 psi})
pressure feed is 90
mm3/sec
(0.0055cu⋅in/sec)
or less.
1E-246 Electronic control fuel injection system (Common rail type)

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0090 247 SCV drive Open/short • Main relay power When SCV drive Approx. 2 Engine stall and/or ON *2
system open circuit of supply voltage is current exceeds sec. engine blow up are
circuit, +B SCV/ 18V or more. specified value possible depending
short or harness • DTC P1630 is not for 2 seconds or on the condition of
ground short detected. more, or when open/short circuit.
• SCV drive duty is difference Black smoke
between 10 — between target emitted, excessive
90%. and actual output
current exceeds Back-up:
specified value Limited injection
for 2 seconds or amount 3 (multi-
more. injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
P0107 71 Barometric Open/short • Key switch input Barometric Approx. 5 Due to back-up ON *2
pressure circuit/ voltage is 18V or pressure sensor sec. equivalent to 2500
sensor fault deterioration more. voltage is lower m (8200 ft)
(low voltage of sensor or • DTC P1630 or than 0.5 V. • Black smoke
fault) harness P1632 is not emitted at high
detected. altitude
• Output shortage at
low altitude
Back-up:
Barometric
pressure default
setting (80 kPa
{11.6 psi})
EGR stopped
P0108 Barometric Short circuit • Key switch input Barometric Approx. 5 Due to back-up ON *2
pressure in sensor or voltage is 18V or pressure sensor sec. equivalent to 2500
sensor fault harness more. voltage is more m (8200 ft)
(high voltage • DTC P1630 or than 3.8 V. • Black smoke
fault) P1632 is not emitted at high
detected. altitude
• Output shortage at
low altitude
Back-up:
Barometric
pressure default
setting (80 kPa
{11.6 psi})
EGR stopped
P0112 22 Intake air Short circuit • Key switch input Intake air Approx. 4 Not in particular ON *2
temperature in sensor or voltage is 18V or temperature sec. Back-up:
sensor fault harness more. sensor voltage is Specified back-up
(low voltage • DTC P1630 or less than 0.1 V. value (depending
fault) P1632 is not on the machine
detected. manufacturer)
P0113 Intake air Open/short • Key switch input Intake air Approx. 4 Not in particular ON *2
temperature circuit/ voltage is 18V or temperature sec. Back-up:
sensor fault deterioration more. sensor voltage is Intake air
(high voltage of sensor or • DTC P1630 or more than 4.95 temperature default
fault) harness P1632 is not V when 3 setting
detected. minutes or more (at starting: −10°C
• 3 minutes or more has elapsed {14°F}, at running:
has elapsed after after starting 25°C {77°F})
starting engine. engine. EGR stopped
 Electronic control fuel injection system (Common rail type) 1E-247

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0117 23 Engine Short circuit • Key switch input Engine coolant Approx. 4 Start ability ON *2
coolant in sensor or voltage is 18V or temperature sec. deteriorates at low
temperature harness more. sensor voltage is temperatures or
sensor fault • DTC P1630 or less than 0.1 V. black smoke
(low voltage P1633 is not emission is
fault) detected. possible, output
lowering depending
on conditions.
Back-up:
Specified back-up
value (depending
on the machine
manufacturer)
P0118 Engine Open/short • Key switch input Engine coolant Approx. 4 At normal ON *2
coolant circuit/ voltage is 18V or temperature sec. temperature: Black
temperature breakage of more. sensor voltage is smoke emission,
sensor fault sensor or • DTC P1630 or more than 4.85 greater engine
(high voltage harness P1633 is not V. combustion noise
fault) detected. possible.
• 3 minutes or more During idling at low
has elapsed after atmospheric
starting engine. temperatures:
Rough idling,
engine stall, white
smoke emission
possible.
Back-up:
Coolant
temperature default
setting
(at starting: −20°C
{−4°F}, at running:
80°C {176°F)
EGR stopped
P0182 211 Fuel Short circuit • Key switch input Combustion Approx. 4 Operationality is ON *2
temperature in sensor or voltage is 18V or temperature sec. affected.
sensor fault harness more. sensor voltage is Back-up:
(low voltage • DTC P1630 or less than 0.1 V. Specified back-up
fault) P1633 is not value (depending
detected. on the machine
manufacturer)
P0183 Fuel Open/short • Key switch input Combustion Approx. 4 Not in particular ON *2
temperature circuit/ voltage is 18V or temperature sec. Back-up:
sensor fault breakage of more. sensor voltage is Fuel temperature
(high voltage sensor or • DTC P1630 or more than 4.85 default setting
fault) harness P1633 is not V. (at starting: −20°C
detected. {−4°F}, at running:
• 3 minutes or more 70°C {158°F)
has elapsed after
starting engine.
P0192 245 Common rail Short circuit • Key switch input Common rail Nearly Engine blow up ON *2
pressure in sensor or voltage is 18V or pressure sensor simultaneo Back-up:
sensor fault harness more. voltage is less us to fault Specified back-up
(low voltage • DTC P1630 or than 0.7 V. occurrence value (depending
fault) P1635 is not on the machine
detected. manufacturer)
P0193 Common rail Open/short • Key switch input Common rail Nearly Engine stall ON *2
pressure circuit/ voltage is 18V or pressure sensor simultaneo possible
sensor fault breakage of more. voltage is more us to fault Output lowering
(high voltage sensor or • DTC P1630 or than 4.5 V. occurrence Back-up:
fault) harness P1635 is not Specified back-up
detected. value (depending
on the machine
manufacturer)
1E-248 Electronic control fuel injection system (Common rail type)

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0201 271 Open circuit Open/short • Main relay power No injector 1 Approx. Intense engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #1 electrical 18V or more. signal exists. idling, output
drive system wiring No. 1 • 70 rpm or more lowering, blow up
cylinder • DTC P0611, fault, output
injector P1261, or P0201 is lowering
not detected. Back-up:
Injection for cylinder
#1 stopped, EGR
stopped
P0202 272 Open circuit Open/short • Main relay power No injector 2 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #2 electrical 18V or more. signal exists. idling, output
drive system wiring No. 2 • 70 rpm or more lowering, blow up
cylinder • DTC P0611, fault
injector P1261 or P0202 is Back-up:
not detected. Injection for cylinder
#2 stopped, EGR
stopped
P0203 273 Open circuit Open/short • Main relay power No injector 3 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #3 electrical 18V or more. signal exists. idling, output
drive system wiring No. 3 • 70 rpm or more lowering, blow up
cylinder • DTC P0611, fault
injector P1261 or P0203 is Back-up:
not detected. Injection for cylinder
#3 stopped, EGR
stopped
P0204 274 Open circuit Open/short • Main relay power No injector 4 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #4 electrical 18V or more. signal exists. idling, output
drive system wiring No. 4 • 70 rpm or more lowering, blow up
cylinder • DTC P0612, fault
injector P1262 or P0204 is Back-up:
not detected. Injection for cylinder
#4 stopped, EGR
stopped
P0205 275 Open circuit Open/short • Main relay power No injector 5 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #5 electrical 18V or more. signal exists. idling, output
drive system wiring No. 5 • 70 rpm or more lowering, blow up
cylinder • DTC P0612, fault
injector P1262 or P0205 is Back-up:
not detected. Injection for cylinder
#5 stopped, EGR
stopped
P0206 276 Open circuit Open/short • Main relay power No injector 6 Approx. Intensive engine ON *1
in injection circuit in supply voltage is monitor input 2.4 sec. vibration, rough
nozzle #6 electrical 18V or more. signal exists. idling, output
drive system wiring No. 6 • 70 rpm or more lowering, blow up
cylinder • DTC P0612, fault
injector P1262 or P0206 is Back-up:
not detected. Injection for cylinder
#6 stopped, EGR
stopped
P0219 543 Overrun Engine • Key switch input When the engine Approx. 1 Output lowering ON *2
speed voltage is 18V or speed exceeds sec. Back-up:
abnormally more. setting value Limited injection
high (depending on amount 1
the machine Limitation is lifted if
manufacturer) the speed
decreases
 Electronic control fuel injection system (Common rail type) 1E-249

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0237 32 Boost Open/short • Key switch input Boost pressure Approx. 3 Operationality is ON *2
pressure circuit/ voltage is 18V or sensor voltage is sec. affected.
sensor fault breakage of more. less than 0.1V. Back-up:
(low voltage sensor or • DTC P1630 or Boost pressure
fault) harness P1634 is not default setting (150
detected. kPa {21.8 psi})
Boost pressure
correction/EGR
stopped
P0238 Boost Short circuit • Key switch input Boost pressure Approx. 3 Black smoke ON *2
pressure in sensor or voltage is 18V or sensor voltage is sec. emitted
sensor fault harness more. more than 4.9V. Back-up:
(high voltage • DTC P1630 or Boost pressure
fault) P1634 is not default setting (150
detected. kPa {21.8 psi})
Boost pressure
correction/EGR
stopped
P0335 15 Crank Open circuit • CMP sensor Cam signal When • Output lowering, ON *1
sensor fault in sensor/ pulse is normal. exists but no trouble white smoke
(no signal) wiring • DTC P0335, crank signal. occurs 14 emission, intense
P0336, P0340, out of 21 engine vibration
P0341 or P1345 is samples. possible
not detected. • Engine stall
• Engine is running. possible (restart is
possible when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
P0336 Crank Broken • CMP sensor Number of pulse When • Output lowering, ON *1
sensor fault teeth/ pulse is normal. for crank signal trouble white smoke
(signal fault) unnecessary • DTC P0335, is mismatched. occurs 14 emission, intense
signal mixed P0336, P0340, out of 21 engine vibration
(such as P0341 or P1345 is samples. possible
short circuit not detected. • Engine stall
with other • Engine is running. possible (restart is
wiring) possible when cam
sensor is normal.)
Back-up:
Control based on
cam when cam
sensor is normal
1E-250 Electronic control fuel injection system (Common rail type)

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0340 14 Cam sensor Open circuit • Key switch input Crank signal When • Behavior does not ON *1
fault (no in sensor/ voltage is 18V or exists but no trouble change during
signal) wiring more. cam signal. occurs 7 engine running.
• Crank pulse is out of 8 • After engine stalls,
normal. samples. engine will not start.
• DTC P0335, Back-up:
P0336, P0340, Engine running
P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
• Engine is running. Unable to identify
cylinder (unable to
restart)
P0341 Cam sensor Broken • Key switch input Number of pulse When • Behavior does not ON *1
fault (signal teeth/ voltage is 18V or for cam signal is trouble change during
fault) unnecessary more. mismatched. occurs 7 engine running.
signal mixed • Crank pulse is out of 8 • After engine stalls,
(such as normal. samples. engine will not start.
short circuit • DTC P0335, Back-up:
with other P0336, P0340, Engine running
wiring) P0341, P1345, or based on crank
P1635 is not when it is normal
detected. After engine stops:
• Engine is running. Unable to identify
cylinder (unable to
restart)
P0380 66 Glow relay Open/short • Key switch input No glow relay When Operationality is not ON *1
fault circuit/ power supply monitor signal trouble affected.
damage of voltage is higher exists against occurs 25 Back-up:
relay or than 16 V but lower glow relay drive out of 30 Specified back-up
harness than 32 V. indication. samples. value (depending
on the machine
manufacturer)
P0381 67 Glow lamp Open/short • Key switch input Glow lamp drive When Operationality is not
fault circuit/ voltage is 18 V or indication signal trouble affected.
damage of more. is unmatched occurs 25 Back-up:
lamp or • DTC P0381 is not with glow lamp out of 30 Back-up: No back-
harness detected. monitor signal. samples. up action
P0487 44 EGR Open/short • Main relay input EGR position Approx. 3 Exhaust gas is ON *1
position fault circuit/ voltage is 18V or output signal is sec. affected.
(Brushless damage of more. abnormal. Back-up:
specification sensor • DTC P1630 or Instruction to fully
) harness P1635 is not close EGR valve
detected.
P0488 45 EGR valve Trouble/ • DTC P1630, Difference Approx. 10 Exhaust gas is ON *2
control fault open circuit P1635, P0487, between target sec. affected.
or valve P0488, or P1635 is valve lift and Back-up:
engage/ not detected. actual position is Instruction to fully
stuck in • Main relay voltage more than 20%. close EGR valve
drive motor is between 20 —
side 32 V.
• Difference
between target
EGR opening
angle and actual
one is 20% or less.
P0522 294 Engine oil Open/short • Key switch input Engine oil Approx. 4 Operationality is not ON *1
pressure circuit/ voltage is 18V or pressure sensor sec. affected.
sensor fault breakage of more. voltage is less Back-up:
(low voltage sensor or • DTC P1633 is not than 0.098 V. Back-up: No back-
fault) harness detected. up action
 Electronic control fuel injection system (Common rail type) 1E-251

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P0523 294 Engine oil Short circuit • Key switch input Engine oil Approx. 4 Operationality is not ON *2
pressure in sensor or voltage is 18V or pressure sensor sec. affected.
sensor fault harness more. voltage is more Back-up:
(high voltage • DTC P1633 is not than 4.85 V. Back-up: No back-
fault) detected. up action
P0601 53 ROM fault ROM fault ROM is faulty. Engine stopped ON *2
— Reflash failure — Back-up:
Engine stopped
P0603 54 EEPROM EEPROM EEPROM is Operationality is not ON *2
fault fault faulty. affected.
— — Back-up:
Back-up: No back-
up action
P0606 51 CPU fault CPU fault Sub-CPU Nearly Output lowering, ON *2
detects main simultaneo hunting
CPU fault in 100 us to fault Back-up:
msec after key occurrence Limited injection
switch ON. amount 2 (multi-
(SUB-CPU injection stopped)
resets CPU.) SUB-CPU stops
— CPU.
Sub-CPU Nearly Unable to start Diagnosed
detects main simultaneo Back-up: for
CPU fault in 100 us to fault Limited injection 100msec
msec after key occurrence amount 2 (multi- only after
switch ON. injection stopped) KEY-ON.
(SUB-CPU SUB-CPU stops
resets CPU.) CPU.
52 CPU Sub-CPU • 480 msec or more RUN-SUB pulse Nearly Output lowering ON *2
monitoring fault has elapsed after does not change simultaneo Back-up:
IC fault key switch ON. for 20 msec or us to fault Limited injection
• Key switch input more. occurrence amount 1
power supply
voltage is higher
than 16 V.
P0611 34 Charge ECU charge • Main relay power When charge Approx. Intensive engine ON *2
circuit fault circuit 1 fault supply voltage is circuit bank 1 1.5 sec. vibration, rough
(bank 1) (internal 18V or more. voltage inside idling, output
burnout, ECU is low. lowering, blow up
open circuit, fault, engine stall
etc.) are possible.
Back-up:
Common 1 stop
(#1, #2, #3 cylinders
stopped), EGR
stopped
P0612 34 Charge ECU charge When charge Approx. Intensive engine ON
circuit fault circuit 2 fault circuit bank 2 1.5 sec. vibration, rough
(bank 2) (internal voltage inside idling, output
burnout, ECU is low. lowering, blow up
open circuit, fault, engine stall
etc.) are possible.
Back-up:
Common 2 stop
(#4, #5, #6 cylinders
stopped), EGR
stopped
P0650 77 Check Lamp fault • Key switch input No check engine Approx. Operationality is not Does *2
engine lamp voltage is 18V or lamp monitor 1.5 sec. affected. not
fault more. signal exists. Back-up: come
• DTC P0650 is not Back-up: No back- on.
detected. up action
1E-252 Electronic control fuel injection system (Common rail type)

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1093 227 No pump Fuel leakage • Key switch input Actual rail Approx. 5 Intense engine ON *1
pressure (large voltage is 18V or pressure is 30 sec. vibration, rough
feed (fuel amount) more. MPa (4351 psi) idling, output
leakage) • 1200 rpm or more or more lower lowering, blow up
• Duty to SCV is than target rail fault, black smoke
33% or less, or pressure. emitted, engine
pressure feed is stall, and excessive
28000mm 3/sec output are possible.
(1.7cu⋅in/sec) or Back-up:
more. Limited injection
• DTC P0192, amount 3 (multi-
P0193, P1093, injection stopped)
P0091, P0092, Target RP upper
P1291, P1292, or limit (80 MPa
P1635 is not {11603 psi})
detected.
P1095 225 Pressure Pressure • Key switch input Pressure limiter Approx. 1 Output lowering ON *1
limiter open limiter is voltage is 18V or is opened. sec. Back-up:
opened. more. Limited injection
• DTC P1095, amount 1
P0192, P0193,
P1630, or P1635 is
not detected.
• 50 rpm or more
P1112 295 Boost Open/short • Key switch input Boost Approx. 4 Operationality is not ON *2
temperature circuit/ voltage is 18V or temperature sec. affected.
sensor fault breakage of more. sensor voltage is Back-up:
(low voltage sensor or • DTC P1634 is not less than 0.1 V. Back-up: No back-
fault) harness detected. up action
P1113 Boost Short circuit • Key switch input Boost Approx. 4 Operationality is not ON *2
temperature in sensor or voltage is 18V or temperature sec. affected.
sensor fault harness more. sensor voltage is Back-up:
(high voltage • Coolant more than Back-up: No back-
fault) temperature 50°C 4.95V. up action
(122°F) or more, or
3 (or 5) minutes
have passed after
engine starting
(depending on the
machine
manufacturer).
• DTC P1634 is not
detected.
P1173 542 Overheat Overheat • Key switch input • Coolant Approx. 5 Operationality is not Does *2
condition voltage is 18V or temperature is sec. affected. not
more. more than Back-up: come
• DTC P1630, 120°C (248°F) Back-up: No back- on.
P1633, P0117, or while engine is up action
P0118 is not operated.
detected.
• Under operation
P1261 158 Injection Open/short • Main relay power No injector 1, 3, Approx. 3 Intensive engine ON *1
nozzle circuit in supply voltage is 5 monitor input sec. vibration, rough
common 1 injector 18V or more. signal exists. idling, output
drive system common 1- • 70 rpm or more lowering, blow up
fault side • None of the fault
electrical following DTC sets Engine stall is
wiring, EDU are detected; DTC possible.
output part P0611, P1261 and Back-up:
fault P0201; DTC Common 1 stop
P0611, P1261 and (#1, #2, #3 cylinders
P0202; DTC stopped), EGR
P0611, P1261 and stopped
P0203.
 Electronic control fuel injection system (Common rail type) 1E-253

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1262 159 Injection Open/short • Main relay power No injector 2, 4, Approx. 3 Intensive engine ON *1
nozzle circuit in supply voltage is 6 monitor input sec. vibration, rough
common 2 injector 18V or more. signal exists. idling, output
drive system common 2- • 70 rpm or more lowering, blow up
fault side • None of the fault
electrical following DTC sets Engine stall is
wiring, EDU are detected; DTC possible.
output part P0612, P1262 and Back-up:
fault P0204; DTC Common 2 stop
P0612, P1262 and (#4, #5, #6 cylinders
P0205; DTC stopped), EGR
P0612, P1262 and stopped
P0206.
P1271 24 Accelerator Difference in • Key switch input Difference in Approx. 3 1 system fault...No Does *1
sensor 1-2 opening voltage is 18V or opening angle sec. back-up not
comparison angle more. between 2 system come
fault between • DTC P1630, accelerator fault...Accelerator on.
accelerator P1631, P1271, sensors 1 and 2 opening angle is
sensors 1-2 P1277, P1278, is 45% or more. controlled to 0%.
is 45% or P1282, or P1283 is Back-up:
more. not detected. 1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1277 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 1 circuit/ voltage is 18V or sensor 1 voltage sec. back-up not
fault (low breakage of more. is lower than 0.2 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1277, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1278 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 1 circuit/ voltage is 18V or sensor 1 voltage sec. back-up not
fault (high breakage of more. is more than 4.9 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1278, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1282 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 2 circuit/ voltage is 18V or sensor 2 voltage sec. back-up not
fault (low breakage of more. is lower than 0.2 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1282, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
1E-254 Electronic control fuel injection system (Common rail type)

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1283 24 Accelerator Open/short • Key switch input Accelerator Approx. 1 1 system fault...No Does *1
sensor 2 circuit/ voltage is 18V or sensor 2 voltage sec. back-up not
fault (high breakage of more. is more than 4.9 2 system come
voltage fault) sensor or • DTC P1630, V. fault...Accelerator on.
harness P1283, or P1631 is opening angle is
not detected. controlled to 0%.
Back-up:
1 system fault...No
back-up
2 system
fault...Accelerator
opening angle is
controlled to 0%.
P1345 16 Cam sensor Camshaft • Key switch input Correct cam When • Behavior does not ON *1
out of phase gear/ voltage is 18V or pulse does not trouble change during
crankshaft more. exist in crank occurs 7 engine running.
gear • DTC P0335, gap position. out of 8 • After engine stalls,
installing P0336, P0340, samples. engine will not start.
angle is out P0341, P1345, or Back-up:
of phase, or P1635 is not Specified back-up
damage in detected. value (depending
gear. • CMP sensor on the machine
pulse is normal. manufacturer)
• Crank pulse is
normal.
P1625 416 Main relay Open/ • Key switch input Main relay Approx. 2 Engine does not ON *2
system fault ground short voltage is 18V or system voltage sec. start.
(Not enter) circuit in more. is 1V or less with Back-up:
harness, • DTC P1630 is not main relay coil Back-up: No back-
relay OFF detected. output ON. up action
anchoring • 3 seconds or
more has elapsed
after key switch
ON.
• Main relay drive
indication ON
Harness +B • DTC P1625 or Relay does not Approx. 5 Vehicle power ON *1
short, relay P0606 is not cut off despite of sec. supply cannot be
ON detected. main relay coil shut off.
anchoring output OFF Back-up:
indication. Back-up: No back-
up action
P1630 36 A/D A/D A/D conversion Immediatel Output lowering, ON *2
conversion conversion failure y Black smoke
fault fault emitted
Back-up:
Analog sensor
system default
— processing
Limited injection
amount 3 (multi-
injection stopped)
Target RP upper
limit (80 MPa
{11603 psi})
 Electronic control fuel injection system (Common rail type) 1E-255

Fault Recovery
Flash DTC Item to be Preconditions when DTC set Behavior when Diagnos
DTC judgment from
code description detected DTC is set condition trouble occurs is lamp
period failure
P1631 55 Voltage fault Power • DTC P1630 is not Key switch Approx. Accelerator opening ON *2
in 5-V power supply detected. power supply 0.5 sec. angle is controlled
supply 1 wiring short • Battery voltage is voltage is 5.5V to 0%.
to sensor, or between 16V — or more, or 4.5V Back-up:
breakage in 32V. or less. Same to accelerator
element/ sensor fault
circuit for
P1632 Voltage fault • DTC P1630 is not Key switch Approx. Due to back-up ON *2
power
in 5-V power detected. power supply 0.5 sec. equivalent to 2500
supply
supply 2 • Battery voltage is voltage is 5.5V m (8200 ft)
regulation
between 16V — or more, or 4.5V • Black smoke
inside ECM.
32V. or less. emitted at high
altitude
• Output shortage at
low altitude
Back-up:
Same to barometric
pressure and intake
air temperature
sensor fault
P1633 Voltage fault • DTC P1630 is not Key switch Approx. Startability ON *2
in 5-V power detected. power supply 0.5 sec. deteriorates at low
supply 3 • Battery voltage is voltage is 5.5V temperatures or
between 16V — or more, or 4.5V black smoke
32V. or less. emission is
possible, output
lowering or
operationality is
affected depending
on conditions.
Back-up:
Same to coolant
temperature, fuel
temperature, and oil
pressure sensor
fault
P1634 Voltage fault • DTC P1630 is not Key switch Approx. Operationality is ON *2
in 5-V power detected. power supply 0.5 sec. affected.
supply 4 • Battery voltage is voltage is 5.5V Back-up:
between 16V — or more, or 4.5V Same to boost
32V. or less. pressure and boost
temperature sensor
fault
P1635 Voltage fault • DTC P1630 is not Key switch Approx. Engine blow up, ON *2
in 5-V power detected. power supply 0.5 sec. output lowering,
supply 5 • Battery voltage is voltage is 5.5V black smoke
between 16V — or more, or 4.5V emission, engine
32V. or less. stall are possible.
Back-up:
Same to rail
pressure sensor
fault and EGR
position sensor fault
U2104 84 CAN Bus CAN • Key switch input Bus-off is At 3 sec. Set to idle speed. ON *3
fault communicati voltage is 20V or detected. continuous Back-up:
on fault more. ly Specified back-up
value (depending
on the machine
manufacturer)
U2106 85 CAN timeout CAN • DTC U2104 is not CAN data At 1 sec. Set to idle speed. ON *3
fault communicati detected. reception does continuous Back-up:
on fault • Key switch input not complete at ly Specified back-up
voltage is 20V or a set time. value (depending
more. on the machine
manufacturer)
1E-256 Electronic control fuel injection system (Common rail type)
About recovery from failure *2
There are three modes for recovery from failure. When the DTC has recovered to normal condition in the
To clear the trouble displayed on the monitor of the ignition cycle that the DTC is detected, the diagnosis
machine, one more ignition cycle may be needed after lamp and back up mode will also be recovered.
the following ignition cycle.
1 2

*1
Key ON
Even if the DTC has restored normally, the diagnosis switch
lamp and back-up mode are not restored in the ignition and
Engine
cycle that the DTC is detected. After turning the key run OFF

switch OFF, DTC diagnosis is performed when the

vehicle starts again. If it is judged as normal, everything
will be recovered to normal from the next ignition cycle. ON
Diag
lamp
1 2 3
OFF

Key ON
switch
and
Engine ON
run OFF
Back-up
mode
OFF

ON
TSWG0166
Diag
lamp
OFF
Name
1. DTC is detected.
2. Recovery to normal.

ON
Back-up
mode
*3
OFF
When the DTC has recovered to normal in the ignition
cycle that the DTC is detected, the back-up mode will
TSWG0165 be recovered normally, but the diagnosis lamp does not
go off.
Name
1. DTC is detected. 1 2
2. Repair and inspection
3. Returned to normal. Key ON
switch
and
Enigne
run OFF

ON
Diag
lamp
OFF

ON
Back-up
mode
OFF

TSWG0207

Name
1. DTC is detected.
2. Recovery to normal.
 Electronic control fuel injection system (Common rail type) 1E-257
DTC: P0087 (Flash code 227) Common rail low pressure fault (No pressure feed in supply
pump)

2 4HK1

3
1

6
7

5 6HK1

TSHK0041

Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
1E-258 Electronic control fuel injection system (Common rail type)

Engine control
module (ECM)

CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V

B+ B+ B+

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

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

0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B

1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W

1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 W

V U

EGR position sensor/EGR motor

EGR valve

CMP sensor Common rail pressure sensor

TSHK0028

Description of circuit
The engine control module (ECM) monitors the
pressure inside of common rail based on the signal
from common rail pressure sensor. If the pressure is
low, ECM controls the SCV of supply pump to increase
the pressure inside of common rail. If fuel supply to the
supply pump is insufficient or the supply pump is faulty,
the pressure inside of common rail cannot be
increased.

Main trouble symptom

• Intense engine vibration
• Rough idling
• Output lowering
• Black smoke emitted
• Excessive output is possible.
 Electronic control fuel injection system (Common rail type) 1E-259
Fuel system filter Back-up mode
• Limited injection amount 3 (multi-injection stopped)
4 • Target RP upper limit (80 MPa {11603 psi})
3
Recovery from failure
Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
5 failure.

The conditions to clear the MIL/DTC

• The present trouble turns to history trouble when
2 the condition is out of the range from DTC set
condition (recovery from failure).
• The check engine lamp will go off after the code
turns to history trouble and the key switch is turned
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and
1 diagnostic switch operation enables to clear DTCs.
TSHK0039

Name Diagnostic aid

1. Fuel pump strainer Followings are suspected as the cause.
2. Pre-fuel filter • Injector internal trouble
3. Electromagnetic pump filter • Supply pump internal trouble
4. Main fuel filter
• Fuel system pipe fault (fuel leakage, clogging,
5. Gauze filter
crush, etc.)
Filter clogging in the fuel system may establish the DTC • Fuel filter fault (clogging)
set condition. Check as required. • Fuel tank fault (clogging)
• Pressure limiter trouble (operation under specified
Preconditions when DTC is set
pressure, degradation of sealability)
900 rpm or more • ECM trouble
DTC set condition • Common rail pressure sensor trouble

Actual rail pressure is 15 MPa (2176 psi) or less for 3 Test description
seconds or more.
Numbers below indicate step numbers in the chart.
10. If the “Common rail pressure sensor” displays more
than the specified value when the common rail
:Desired rail puressure pressure sensor connector is removed, the circuit
:Actual rail presure beyond the sensor is normal including ECM.
Absolute pressure

30MPa(4351psi)

Actual 1 P1093

t2 > 5sec

t1 > 3sec
15MPa Actual 2
(2176psi) P0087

TSHK0130

Action taken when DTC is set

Check engine lamp comes on.
1E-260 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check the fuel system in the following
procedure.
1. Check the high pressure pipe and low
pressure pipe for looseness in the
connection (fuel leakage), crush or
clogging.
2 2. Check the fuel pipe, fuel filter, and inside —
of the fuel tank for freeze or waxing. (at
cold temperature)
3. Check the feed pipe inside the fuel tank for
clogging of foreign matter.
Is the fuel system normal? Go to Step 4. Go to Step 3.
Repair or replace the faulty part.
3 —
Is the procedure completed? Go to Step 18. —
Check for rise of fuel level in the oil level gauge
4 or light oil odor. —
Is the trouble detected? Go to Step 5. Go to Step 6.
Check the connection of the fuel pipe in each
injector, and replace the injector if oil leakage is
confirmed.

5 Note: —
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? Go to Step 18. —

Is the scan tool (KW communication)
6 —
available? Go to Step 7. Go to Step 20.
Check the injector.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2. Start the engine.
3. Select the “Actuator test” from the menu.
7 —
4. Select the “Injection stop at each injector”
in the “Common rail system”.
5. Press the “OFF” soft key to stop the fuel
injection in the cylinder one by one, and
check the change in engine sound.
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 9. Go to Step 8.
 Electronic control fuel injection system (Common rail type) 1E-261

Step Action Value YES NO

Replace the injector in the cylinder of which
engine sound did not change when it is
stopped.

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

Is the procedure completed? Go to Step 18. —

Check the common rail pressure.
1. Turn the key switch to “ON”.
2. Check for “Common rail pressure” on the
At engine
data display using scan tool.
stopped:
3. Start the engine and run it at idle. Differential
4. Check for “Differential fuel rail pressure” pressure −30
9 on the data display using scan tool. MPa (−4351
5. Race it quickly for about 5 times. psi); At idling,
6. Check for “Differential fuel rail pressure” racing: ±5
on the data display using scan tool. MPa (±725
psi)
Is each value of “Fuel rail pressure” (at engine
stopped, idling and racing) around the
specified value? Go to Step 16. Go to Step 10.
1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Turn the key switch to “ON”.
10 4.8V
4. Check for “Common rail pressure sensor”
on the data display using scan tool.
Is the “Common rail pressure sensor” more
than the specified value? Go to Step 13. Go to Step 11.
1. Check the signal circuit between common
rail pressure sensor and ECM for short
circuit to signal circuits of other sensors
11 using breaker box or DMM. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 18. Go to Step 12.
12 Is EMPS available? — Go to Step 13. Go to Step 14.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this
section for check and rewriting of ECM.

13 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 1. Go to Step 14.

1E-262 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
14 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 16. Go to Step 15.

Replace the common rail (common rail
15 pressure sensor). —
Is the procedure completed? Go to Step 18. —
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2. Start the engine.
3. Select the “Actuator test” from the menu. ±5 MPa (±725
16
4. Select the “Rail pressure control” in the psi)
“Common rail system”.
5. Press the “Up” soft key to check the value
of “Differential fuel pressure”.
Is “Differential fuel rail pressure” within the
specified value? Go to Step 18. Go to Step 17.
Replace the supply pump.
17 —
Is the procedure completed? Go to Step 18. —
Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
18 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0087 detected? Go to Step 2. Go to Step 19.
Check if DTC is detected.
19 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
Use the injector checker to stop injection in the
injector, and check the change in engine
sound.
20 —
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 22. Go to Step 21.
 Electronic control fuel injection system (Common rail type) 1E-263

Step Action Value YES NO

Replace the injector in the cylinder of which
engine sound did not change when it is
stopped.

21 Note: —
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? Go to Step 18. —

1. Turn the key switch to OFF.
2. Disconnect the common rail pressure
sensor connector.
3. Measure the voltage between the common
22 rail pressure sensor power supply terminal 4.8V
and the ground.
Is the DMM indication more than the specified
value? Go to Step 24. Go to Step 23.
1. Check the signal circuit between common
rail pressure sensor and ECM for short
circuit to signal circuits of other sensors
23 using breaker box or DMM. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 18. Go to Step 12.
Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
24 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0087 detected? Go to Step 17. Go to Step 19.
1E-264 Electronic control fuel injection system (Common rail type)
About common rail pressure sensor 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.

3 2 1

TSWG0055

Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply Name
1. Breaker box
2. DMM
Characteristics of common rail pressure sensor

(V)
4.2

0 200(29008)
MPa(psi)
TSWG0201

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
11, 23 Short circuit to Voltage • Disconnect the 82 - Ground 0V 1V or
other signal measurement sensor 90 - Ground more
circuit connector.
• Key switch “ON”
 Electronic control fuel injection system (Common rail type) 1E-265
DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage)

2 4HK1

3
1

6
7

5 6HK1

TSHK0041

Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
1E-266 Electronic control fuel injection system (Common rail type)

Engine control
module (ECM)

CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V

B+ B+ B+

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

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

0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B

1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W

1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 W

V U

EGR position sensor/EGR motor

EGR valve

CMP sensor Common rail pressure sensor

TSHK0028

Description of circuit • Rough idling

The common rail pressure sensor detects the common • Output lowering
rail internal pressure. The common rail pressure sensor • Engine blow up fault
is installed to the common rail. As the common rail • Black smoke emitted
internal pressure changes depending on engine • Excessive output possible
condition, output voltage of the common rail pressure
sensor will change (if the common rail internal fuel Preconditions when DTC is set
pressure is low, output voltage becomes low, if the
pressure is high, the output voltage becomes high as 1st step
well). The engine control module (ECM) reads this • Key switch input voltage is 18V or more.
output voltage change, converting it into common rail • DTC P0088, P0192, P0193, or P1635 is not
internal pressure, to utilize for control. Dedicated detected.
communication circuits are used for the sensor power • Actual rail pressure is 2 MPa (290 psi) or more,
supply (5V), SIG, and ground in the common rail and 70 rpm or more.
pressure sensor, which are connected to the ECM. 2nd step
Also, the sensor circuit is shielded to avoid electrical • Battery voltage is normal.
noise etc.
• DTC P0088, P0192, P0193, or P1635 is not
detected.
Main trouble symptom
• Actual rail pressure is 2 MPa (290 psi) or more,
• Intense engine vibration and 70 rpm or more.
 Electronic control fuel injection system (Common rail type) 1E-267
DTC set condition Back-up mode
1st step • Limited injection amount 3 (multi-injection stopped)
• Rail pressure is more than 185 MPa (26832 psi) for • Target RP upper limit (80 MPa {11603 psi})
5 seconds or more.
• Common rail pressure sensor voltage is 3.9 V or Recovery from failure
more. Refer to “List of diagnostic trouble code” and “About
2nd step recovery from failure” in this section for recovery from
• 1st stage is completed, and rail pressure is more failure.
than 190 MPa (27557 psi) for 5 seconds or more.
• Common rail pressure sensor voltage is 4.0 V or The conditions to clear the MIL/DTC
more. • The present trouble turns to history trouble when
the condition is out of the range from DTC set
Note: condition (recovery from failure).
Pressure limiter opens at 200 MPa (29008 psi), and
• The diagnosis lamp will go off after the code turns
DTC P1095 is detected in this case.
to history trouble and the key switch is turned
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.

Diagnostic aid
Common rail
presure

T>1sec=P1095
If the intermittent trouble is suspected, followings may
be the cause.
200 MPa • Improper connection of harness connector
(29008psi)
• Defective harness routing
190 MPa T • Worn harness cladding
(27557psi)
185 MPa
• Wire disconnection inside harness cladding
(26832psi) Following inspections are necessary to detect these
T causes.
T>5sec=P0088
• Improper connection of harness connector and
ECM connector
– Poor connection of terminal from connector
– Unmatched terminals are fitted.
TSHK0043
– Damage of connector lock
Action taken when DTC is set – Poor contact between terminal and wire
• Trouble is displayed on the monitor of the • Damaged harness
machine* or diagnosis lamp comes on. (* Nothing – Visually check the harness for damage.
is displayed depending on the machine – Check the relevant items on the scan tool data
manufacturer) display while moving the connector and the
harness which are related to the sensor. The
variation of the display indicates the faulty part.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Start the engine.
2. Check the DTC.
3. Are the fuel-related parts only just
replaced?
Air bleeding may not be performed
2 sufficiently after replacing fuel-related —
parts. Bleed air again. Check the DTC
after bleeding air.
Is any of the P0088, P0192, P0193, or P1635 Go to the relevant
detected? DTC detected. Go to Step 3.
1E-268 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Is the scan tool (KW communication)
3 —
available? Go to Step 4. Go to Step 5.
1. Turn the key switch to “OFF” for more than
30 seconds.
Differential
2. Start the engine. pressure ±5
4 3. Check for “Differential fuel rail pressure” MPa (±725
on the data display using scan tool. psi)
(at idle)
Is “Differential fuel rail pressure” within the Go to “Diagnostic
specified value? Go to Step 5. aid”.
1. Check the fuel return pipe between the
supply pump and the fuel tank for
breakage, twist, etc.
2. Check for clogging or twisting in the vent
5 hose of the fuel tank. —
3. Check for foreign matter in the fuel tank.
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 8. Go to Step 6.
1. Replace the common rail (common rail
pressure sensor) since it seems that
abnormal value of the pressure sensor is
detected.

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

2. Check the DTC.

Is the trouble detected? Go to Step 7. Go to Step 8.
Replace the supply pump.

Note:
7 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 8. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
8 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0088 detected? Go to Step 2. Go to Step 9.
Check if other DTC is detected.
9 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-269
About common rail pressure sensor

3 2 1

TSWG0055

Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply

Characteristics of common rail pressure sensor

(V)
4.2

0 200(29008)
MPa(psi)
TSWG0201
1E-270 Electronic control fuel injection system (Common rail type)
DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in
supply pump)

2 4HK1

3
1

6
7

5 6HK1

TSHK0041

Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
 Electronic control fuel injection system (Common rail type) 1E-271

Engine control
module (ECM)

CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V

B+ B+ B+

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

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

0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B

1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W

1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 W

V U

EGR position sensor/EGR motor

EGR valve

CMP sensor Common rail pressure sensor

TSHK0028

Description of circuit • Rough idling

The common rail pressure sensor detects the common • Output lowering
rail internal pressure. The common rail pressure sensor • Engine blow up fault
is installed to the common rail. As the common rail • Black smoke emitted
internal pressure changes depending on engine • Excessive output possible
condition, output voltage of the common rail pressure
sensor will change (if the common rail internal fuel Preconditions when DTC is set
pressure is low, output voltage becomes low, if the
pressure is high, the output voltage becomes high as • Key switch input voltage is 18V or more.
well). The engine control module (ECM) reads this • DTC P0089, P0192, P0193, or P1635 is not
output voltage change, converting it into common rail detected.
internal pressure, to utilize for control. Dedicated • Coolant temperature is 60°C (140°F) or more, and
communication circuits are used for the sensor power 375 rpm or more.
supply (5V), SIG, and ground in the common rail • Duty to SCV is 40% or less, or SCV target
pressure sensor, which are connected to the ECM. pressure feed is 90 mm3/sec (0.0055 cu⋅in/sec) or
Also, the sensor circuit is shielded to avoid electrical less.
noise etc.

Main trouble symptom

• Intense engine vibration
1E-272 Electronic control fuel injection system (Common rail type)
DTC set condition • Using the scan tool, or memory clear switch and
• Actual rail pressure is 40 MPa (5802 psi) or more diagnostic switch operation enables to clear DTCs.
higher than target rail pressure for 5 seconds or
more. 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. (* Nothing • Defective harness routing
is displayed depending on the machine • Worn harness cladding
manufacturer) • Wire disconnection inside harness cladding
Following inspections are necessary to detect these
Back-up mode causes.
• Limited injection amount 3 (multi-injection stopped) • Improper connection of harness connector and
• Target RP upper limit (80 MPa {11603 psi}) ECM connector
– Poor connection of terminal from connector
Recovery from failure – Unmatched terminals are fitted.
Refer to “List of diagnostic trouble code” and “About – Damage of connector lock
recovery from failure” in this section for recovery from – Poor contact between terminal and wire
failure.
• Damaged harness
The conditions to clear the MIL/DTC – Visually check the harness for damage.
– Check the relevant items on the scan tool data
• The present trouble turns to history trouble when
display while moving the connector and the
the condition is out of the range from DTC set
harness which are related to the sensor. The
condition (recovery from failure).
variation 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
“OFF” then “ON” again.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Start the engine.
2. Check the DTC.
2 —
Is any of the P0089, P0192, P0193, or 1635 Go to the relevant
detected? DTC detected. Go to Step 3.
Is the scan tool (KW communication)
3 —
available? Go to Step 4. Go to Step 12.
1. Turn the key switch to “OFF” for more than
30 seconds.
2. Start the engine. Differential
3. Check for “Differential fuel rail pressure” pressure ±5
4
on the data display using scan tool. MPa (±725
psi)
Is “Differential fuel rail pressure” within the Go to “Diagnostic
specified value? aid”. Go to Step 5.
1. Turn the key switch to “OFF”.
2. Wait for 2 minutes before the common rail
internal pressure goes down.
3. Turn the key switch to “ON”. Do not start Differential
engine. pressure
5
−30 MPa (−
4. Check for “Differential fuel rail pressure”
4351 psi)
on the data display using scan tool.
Is “Differential fuel rail pressure” the specified
value? Go to Step 6. Go to Step 7.
 Electronic control fuel injection system (Common rail type) 1E-273

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the SCV connector.
3. Check the SCV harness connector
terminal for poor contact, intermittent
trouble, etc.
4. Disconnect the ECM harness connector.
6 —
5. Check the ECM harness connector
terminal for poor contact, intermittent
trouble, etc.
6. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 10. Go to Step 9.
1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Check the common rail pressure sensor
harness connector terminal for poor
contact, intermittent trouble, etc.
7 4. Disconnect the ECM harness connector. —
5. Check the ECM harness connector
terminal for poor contact, intermittent
trouble, etc.
6. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 10. Go to Step 8.
Replace the common rail (common rail
pressure sensor).

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

Is the procedure completed? Go to Step 10. —

Replace the supply pump.

Note:
9 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 10. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
10 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is the DTC P1093 detected? Go to Step 2. Go to Step 11.
1E-274 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check if other DTC is detected.
11 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Visually check the harness between the
ECM and the common rail pressure
sensor for damage.
12 2. If the trouble is detected, repair as —
required.
Is the procedure completed? Go to Step 5. Go to Step 6.

About common rail pressure sensor On-board check procedure for sensors

3 2 1

2 1

TSWG0055 TSWG0197

Name Name
1. Power supply 1. Coupling connector between engine — the
2. Signal machine
3. GND 2. Machine harness
3. Sensor connector
4. Engine harness
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
harness. 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-275
DTC: P0090 (Flash code 247) SCV drive system open circuit, +B short or ground short

2 E-161

SCV

1 E-161

0.75 0.75
R/B R/W

1 H-6 2 H-6

97 E-56 89 E-56 105 E-56 113 E-56

Engine control
module(ECM)

B+

TSHK0027

Description of circuit • 300 rpm or more, or actual rail pressure exceeds

The suction control valve (SCV) controls the fuel feed target rail pressure.
pressure amount to the common rail. Once the SCV
installed to the supply pump receives the signal DTC set condition
(voltage), the SCV closes the valve and pressure-feeds • When SCV drive current exceeds specified value
fuel from the supply pump to the common rail. The for 2 seconds or more.
engine control module (ECM) operates the SCV to • When the difference between target and actual
adjust the common rail pressure. current exceeds specified value for 2 seconds or
more.
Main trouble symptom
• Engine stall and/or engine blow up are possible Action taken when DTC is set
depending on the condition of open/short circuit. • Trouble is displayed on the monitor of the
• Black smoke emitted machine* or diagnosis lamp comes on. (* Nothing
• Excessive output is displayed depending on the machine
manufacturer)
Preconditions when DTC is set
Back-up mode
• Main relay power supply voltage is 18V or more.
• DTC P0090 is not detected. • Limited injection amount 3 (multi-injection stopped)
• Target RP upper limit (80 MPa {11603 psi})
1E-276 Electronic control fuel injection system (Common rail type)
Recovery from failure Diagnostic aid
Refer to “List of diagnostic trouble code” and “About If the intermittent trouble is suspected, followings may
recovery from failure” in this section for recovery from be the cause.
failure. • Improper connection of harness connector
• Defective harness routing
The conditions to clear the MIL/DTC
• Worn harness cladding
• The present trouble turns to history trouble when • Wire disconnection inside harness cladding
the condition is out of the range from DTC set Following inspections are necessary to detect these
condition (recovery from failure). causes.
• The diagnosis lamp will go off after the code turns • Improper connection of harness connector and
to history trouble and the key switch is turned ECM connector
“OFF” then “ON” again.
– Poor connection of terminal from connector
• Using the scan tool, or memory clear switch and
– Unmatched terminals are fitted.
diagnostic switch operation enables to clear DTCs.
– Damage of connector lock
– Poor contact between terminal and wire
• Damaged harness
– Visually check the harness for damage.
– Check the relevant items on the scan tool data
display while moving the connector and the
harness which are related to the sensor. The
variation of the display indicates the faulty part.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 4.
1. Connect the scan tool.
2. Start the engine.
3. Check for “SCV F/B” on the data display
3 using scan tool. 50mA

Is the value of “SCV F/B” less than the

specified value? Go to Step 4. Go to Step 5.
1. Check for followings in the circuit between
SCV and ECM using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
4 —
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 6.
 Electronic control fuel injection system (Common rail type) 1E-277

Step Action Value YES NO

1. Check for followings in the circuit between
SCV and ECM using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
5 —
• Short circuit between terminals
• Short circuit to power supply circuit or
ignition power supply circuit
• Short circuit to other signal circuit
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 6.
Check the SCV body. Between
1. Turn the key switch to “OFF”. terminals:
2. Disconnect the harness from the SCV. 3.2±0.3 Ω;
6 Each terminal
3. Measure the resistance between the SCV
to SCV body:
connector terminals.
∞Ω (at normal
Is the resistance specified value? temperature) Go to Step 8. Go to Step 7.
Replace the supply pump (SCV).

Note:
7 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
8 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Start the engine, and test run with the
“Preconditions when DTC is set”.
5. Check the DTC.
Go to “Diagnostic
Is the DTC P0090 detected? Go to Step 9. aid”.
9 Is EMPS available? — Go to Step 10. Go to Step 11.
1E-278 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

10 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. Go to Step 11.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
12 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Start the engine, and test run with the
“Preconditions when DTC is set”.
5. Check the DTC.
Is the DTC P0090 detected? Go to Step 2. Go to Step 13.
Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-279
About SCV
4HK1

Name
TSHK0007 1. SCV-HI
2. SCV-LO
6HK1

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.
1

TSHK0008

Name
1. SCV

Name
1. Breaker box
2. DMM
1E-280 Electronic control fuel injection system (Common rail type)

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
4 Open circuit/ Resistance • Disconnect the 105 - SCV terminal 5Ω or less 10 MΩ or
high measurement SCV connector. 113 - SCV terminal more
resistance • Key switch “OFF” 89 - SCV terminal
97 - SCV terminal
Short circuit to Resistance • Disconnect the 105 - Ground 10 MΩ or 100Ω or
ground measurement SCV connector. 113 - Ground more less
• Key switch “OFF” 89 - Ground
97 - Ground
5 Short circuit Resistance • Disconnect the 105 - 89 10 MΩ or 100Ω or
between measurement SCV connector. 105 - 97 more less
terminals • Key switch “OFF” 113 - 89
113 - 97
Short circuit to Voltage • Disconnect the 105 - Ground 0V 18V or
power supply measurement SCV connector. 113 - Ground more
circuit • Key switch “ON” 89 - Ground
97 - Ground
Short circuit to Voltage • Disconnect the 105 - Ground 0V 1V or
other signal measurement SCV connector. 113 - Ground more
circuit • Key switch “ON” 89 - Ground
97 - Ground

On-board check procedure for sensors • If both steps 1 and 2 are faulty, repair the
harness. 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

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
 Electronic control fuel injection system (Common rail type) 1E-281
DTC: P0107 (Flash code 71) Barometric pressure sensor circuit input is low (open circuit
or ground short).

A A Engine control
module (ECM)

Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V

Vcc

37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Machine
control unit

CAN HIGH CAN LOW

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

6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor

TSHK0029

Description of circuit Preconditions when DTC is set

The barometric pressure sensor detects the barometric • Key switch input voltage is 18V or more.
pressure. The barometric pressure sensor is installed • DTC P1630 or P1632 is not detected.
to the machine. As the barometric pressure changes
depending on altitude and weather condition, output DTC set condition
voltage of the barometric pressure sensor will change
• Barometric pressure sensor voltage is 0.5V or less
(if the barometric pressure is low, output voltage
for 5 seconds or more.
becomes low, if the barometric pressure is high, the
output voltage becomes high as well). The engine
Action taken when DTC is set
control module (ECM) reads this output voltage
change, converting it into barometric pressure, to utilize • Trouble is displayed on the monitor of the
for optimizing the fuel injection control and for machine* or diagnosis lamp comes on. (* Nothing
calculating the relative boost pressure. is displayed depending on the machine
manufacturer)
Main trouble symptom
Due to back-up equivalent to 2500 m (8200 ft)
• Black smoke emitted at high altitude
• Output shortage at low altitude
1E-282 Electronic control fuel injection system (Common rail type)
Back-up mode Following inspections are necessary to detect these
• Barometric pressure default setting (80 kPa {11.6 causes.
psi}) • Improper connection of harness connector and
• EGR stopped ECM connector
– Poor connection of terminal from connector
Recovery from failure – Unmatched terminals are fitted.
Refer to “List of diagnostic trouble code” and “About – Damage of connector lock
recovery from failure” in this section for recovery from – Poor contact between terminal and wire
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
the condition is out of the range from DTC set harness which are related to the sensor. The
condition (recovery from failure). variation of the display indicates the faulty part.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs. Test description
Numbers below indicate step numbers in the chart.
Diagnostic aid 3. In case of present trouble, the “Barometric pressure
If the intermittent trouble is suspected, followings may sensor” displays less than the specified value. If more
be the cause. than the specified value, identify the cause by referring
• Improper connection of harness connector to “Diagnostic aid”.
• Defective harness routing 5. If the “Barometric pressure sensor” displays more
than the specified value when terminals between the
• Worn harness cladding
barometric pressure sensor connector are shorted, the
• Wire disconnection inside harness cladding circuit beyond the sensor is normal including ECM.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 14.
Check the value for barometric pressure
sensor using scan tool.
1. Connect the scan tool.
2. Start the engine.
3 0.5V
3. Check the value for “Barometric pressure
sensor” using scan tool.
Is the “Barometric pressure sensor” less than Go to “Diagnostic
the specified value? Go to Step 4. aid”.
Check for installation condition of the
barometric pressure sensor, ECM and coupling
connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 9. Go to Step 5.
 Electronic control fuel injection system (Common rail type) 1E-283

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the barometric pressure
sensor connector.
3. Short between the barometric pressure
sensor connector power supply terminal
5 and the signal terminal using jump cable. 4.8V
4. Turn the key switch to “ON”.
5. Check the value for “Barometric pressure
sensor” using scan tool.
Is the “Barometric pressure sensor” more than
the specified value? Go to Step 8. Go to Step 6.
1. Check for followings in the power supply
circuit between ECM and barometric
pressure sensor using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.

Note:
6 If breaker box is not available, refer to “On- —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 9. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and barometric pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 —
• Short circuit to barometric pressure
sensor ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the barometric pressure sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
1E-284 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

10 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. Go to Step 11.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
12 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0107 detected? Go to Step 2. Go to Step 13.
Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine. 127 kPa (184
2. Check the display of barometric pressure. psi)
14
Does the display of “Barometric pressure” (Displayed Go to “Diagnostic
show error value? error value) Go to Step 15. aid”.
Check for installation condition of the
barometric pressure sensor, ECM and coupling
connector.
(Check the barometric pressure sensor circuit
for open circuit or ground short.)
15 1. Check for disconnection, play or —
looseness in the connection.
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 9. Go to Step 16.
 Electronic control fuel injection system (Common rail type) 1E-285

Step Action Value YES NO

1. Check for followings in the power supply
circuit between ECM and barometric
pressure sensor using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.

Note:
16 If breaker box is not available, refer to “On- —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 17.
1. Check for followings in the signal circuit
between ECM and barometric pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
17 —
• Short circuit to barometric pressure
sensor ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 8.

About barometric pressure sensor Name

1. Power supply
2. GND
3. Signal

1 2 3

TSWG0058
1E-286 Electronic control fuel injection system (Common rail type)
Characteristics of barometric pressure sensor Breaker box inspection procedure
The output voltage of barometric pressure sensor Perform the inspection in the following procedure if
changes according to the barometric pressure. there is such an instruction to use breaker box in the
The scan tool with CAN communication displays a fixed step. After inspection, return to the diagnostic step.
value when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value if
the value of 40 kPa (5.8 psi) or 127 kPa (18.4 psi) is not
changed.
When error occurs, error value (127 kPa {18.4 psi}) is
displayed. 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
display both voltage and physical value.

(V)

2.279198

Name
1. Breaker box
2. DMM
1.009671

40(5.8) 120(17.4) kPa(psi)

TSWG0205

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Open circuit/ Resistance • Disconnect the 61 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector power less more
resistance connector. supply terminal
• Key switch “OFF”
7 Short circuit to Resistance • Disconnect the 71 - 60 10 MΩ or 100Ω or
ground circuit/ measurement sensor 71 - Ground more less
ground connector.
• Key switch “OFF”
Open circuit/ Resistance • Disconnect the 71 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector signal less more
resistance connector. terminal
• Key switch “OFF”
 Electronic control fuel injection system (Common rail type) 1E-287
On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the harness.
If only step 1 is faulty, replace the sensor.
1E-288 Electronic control fuel injection system (Common rail type)
DTC: P0108 (Flash code 71) Barometric pressure sensor circuit input is high (+5 V short)

A A Engine control
module (ECM)

Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V

Vcc

37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Machine
control unit

CAN HIGH CAN LOW

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

6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor

TSHK0029

Description of circuit Preconditions when DTC is set

The barometric pressure sensor detects the barometric • Key switch input voltage is 18V or more.
pressure. The barometric pressure sensor is installed • DTC P1630 or P1632 is not detected.
to the machine. As the barometric pressure changes
depending on altitude and weather condition, output DTC set condition
voltage of the barometric pressure sensor will change
• Barometric pressure sensor voltage is 3.8 V or
(if the barometric pressure is low, output voltage
more for 4 seconds or more.
becomes low, if the barometric pressure is high, the
output voltage becomes high as well). The engine
Action taken when DTC is set
control module (ECM) reads this output voltage
change, converting it into barometric pressure, to utilize • Trouble is displayed on the monitor of the
for optimizing the fuel injection control and for machine* or diagnosis lamp comes on. (* Nothing
calculating the relative boost pressure. is displayed depending on the machine
manufacturer)
Main trouble symptom
Back-up mode
Due to back-up equivalent to 2500 m (8200 ft)
• Black smoke emitted at high altitude • Barometric pressure default setting (80 kPa {11.6
psi})
• Output shortage at low altitude
• EGR stopped
 Electronic control fuel injection system (Common rail type) 1E-289
Recovery from failure Following inspections are necessary to detect these
Refer to “List of diagnostic trouble code” and “About causes.
recovery from failure” in this section for recovery from • Improper connection of harness connector and
failure. ECM connector
– Poor connection of terminal from connector
The conditions to clear the MIL/DTC – Unmatched terminals are fitted.
• The present trouble turns to history trouble when – Damage of connector lock
the condition is out of the range from DTC set – Poor contact between terminal and wire
condition (recovery from failure). • Damaged harness
• Using the scan tool, or memory clear switch and – Visually check the harness for damage.
diagnostic switch operation enables to clear DTCs.
– Check the relevant items on the scan tool data
display while moving the connector and the
Diagnostic aid
harness which are related to the sensor. The
If the intermittent trouble is suspected, followings may variation of the display indicates the faulty part.
be the cause.
• Improper connection of harness connector Test description
• Defective harness routing Numbers below indicate step numbers in the chart.
• Worn harness cladding 3. In the case of present trouble, the “Barometric
• Wire disconnection inside harness cladding pressure sensor” displays more than the specified
value. If less than the specified value, identify the cause
by referring to “Diagnostic aid”.
5. If the “Barometric pressure sensor” displays more
than the specified value when the barometric pressure
sensor connector is removed, the circuit beyond the
sensor is normal including ECM.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 14.
Check the value for barometric pressure
sensor using scan tool.
1. Connect the scan tool.
2. Start the engine.
3 3.8V
3. Check the value for “Barometric pressure
sensor” using scan tool.
Is the “Barometric pressure sensor” more than Go to “Diagnostic
the specified value? Go to Step 4. aid”.
Check for installation condition of the
barometric pressure sensor, ECM and coupling
connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 5.
1E-290 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the barometric pressure
sensor connector.
3. Turn the key switch to “ON”.
5 0V
4. Check the value for “Barometric pressure
sensor” using scan tool.
Is the “Barometric pressure sensor” less than
the specified value? Go to Step 8. Go to Step 6.
1. Check the signal circuit between ECM and
barometric pressure sensor for short
circuit to the power supply circuit or
ignition power supply circuit using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —

Important:
If the barometric pressure sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the ground circuit
between ECM and barometric pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the barometric pressure sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
 Electronic control fuel injection system (Common rail type) 1E-291

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

10 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. Go to Step 11.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
12 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0108 detected? Go to Step 2. Go to Step 13.
Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine. 127 kPa (18.4
2. Check the display of barometric pressure. psi)
14
Does the display of “Barometric pressure” (Displayed Go to “Diagnostic
show more than error value? error value) Go to Step 15. aid”.
1E-292 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check for installation condition of the
barometric pressure sensor, ECM and coupling
connector.
(Check the barometric pressure sensor circuit
for short to +5V line or battery power supply
circuit.)
15 —
1. Check for play or looseness in the
connection.
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 16.
1. Check the signal circuit between ECM and
barometric pressure sensor for short
circuit to the power supply circuit or
ignition power supply circuit using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
16 board check procedure for sensors”. —

Important:
If the barometric pressure sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 12. Go to Step 17.
1. Check for followings in the ground circuit
between ECM and barometric pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
17 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 8.
 Electronic control fuel injection system (Common rail type) 1E-293
About barometric pressure sensor 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.

1 2 3

TSWG0058

Name
1. Power supply
2. GND
3. Signal Name
1. Breaker box
Characteristics of barometric pressure sensor 2. DMM

The output voltage of barometric pressure sensor

changes according to the barometric pressure.
The scan tool with CAN communication displays a fixed
value when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value if
the value of 40 kPa (5.8 psi) or 127 kPa (18.4 psi) is not
changed.
When error occurs, error value (127 kPa {18.4 psi}) is
displayed. 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
display both voltage and physical value.

(V)

2.279198

1.009671

40(5.8) 120(17.4) kPa(psi)

TSWG0205
1E-294 Electronic control fuel injection system (Common rail type)

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Voltage • Disconnect the 71 - Ground 0V 18V or
power supply measurement sensor more
circuit connector.
• Key switch “ON”
7 Open circuit/ Resistance • Disconnect the 60 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector ground less more
resistance connector. terminal
• Key switch “OFF”
 Electronic control fuel injection system (Common rail type) 1E-295
DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND
short, short circuit)

A A Engine control
module (ECM)

Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V

Vcc

37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Machine
control unit

CAN HIGH CAN LOW

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

6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor

TSHK0029

Description of circuit Preconditions when DTC is set

The intake air temperature (IAT) sensor is the • Key switch input voltage is 18V or more.
thermistor type and the value of resistance changes • DTC P1630 or P1632 is not detected.
according to the temperature. The resistance is low
when the intake air temperature is high, and is high DTC set condition
when the temperature is low. The ECM energizes 5 V to
• IAT sensor voltage is 0.1V or less for 4 seconds or
the IAT sensor through the pull up resistance, and
more.
calculate the intake air temperature from the change in
voltage, to utilize various control such as fuel injection
Action taken when DTC is set
control. If the resistance is low (temperature is high),
the voltage becomes low; if the resistance is high • Trouble is displayed on the monitor of the
(temperature is low), the voltage becomes high. machine* or diagnosis lamp comes on. (* Nothing
is displayed depending on the machine
Main trouble symptom manufacturer)
• White smoke emission possible when starting at
Back-up mode
low temperatures
• Intake air temperature default setting
• (at starting: −10°C {14°F}, at running: 25°C {77°F})
1E-296 Electronic control fuel injection system (Common rail type)
• EGR stopped • Wire disconnection inside harness cladding
Following inspections are necessary to detect these
Recovery from failure causes.
Refer to “List of diagnostic trouble code” and “About • Improper connection of harness connector and
recovery from failure” in this section for recovery from ECM connector
failure. – Poor connection of terminal from connector
– Unmatched terminals are fitted.
The conditions to clear the MIL/DTC – Damage of connector lock
• The present trouble turns to history trouble when – Poor contact between terminal and wire
the condition is out of the range from DTC set • Damaged harness
condition (recovery from failure).
– Visually check the harness for damage.
• Using the scan tool, or memory clear switch and
– Check the relevant items on the scan tool data
diagnostic switch operation enables to clear DTCs.
display while moving the connector and the
harness which are related to the sensor. The
Diagnostic aid
variation of the display indicates the faulty part.
• To make sure the correct performance of the IAT
sensor, check with various temperatures using the Test description
reckoner table between temperature and
Numbers below indicate step numbers in the chart.
resistance. If the sensor is faulty, operationality
3. In the case of present trouble, the “Intake air
may be affected.
temperature sensor” displays less than the specified
If the intermittent trouble is suspected, followings may
value. If more than the specified value, identify the
be the cause.
cause by referring to “Diagnostic aid”.
• Improper connection of harness connector 5. If the “Intake air temperature sensor” displays more
• Defective harness routing than the specified value when the IAT sensor connector
• Worn harness cladding is removed, the circuit beyond the sensor is normal
including ECM.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 13.
Check the value for IAT sensor using scan tool.
1. Connect the scan tool.
2. Start the engine.
3 3. Check the value for “Intake air 0.1V
temperature sensor” using scan tool.
Is the “Intake air temperature sensor” less than Go to “Diagnostic
the specified value? Go to Step 4. aid”.
Check for installation condition of the IAT
sensor, ECM and coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 5.
1. Turn the key switch to “OFF”.
2. Disconnect the IAT sensor connector.
3. Turn the key switch to “ON”.
5 4. Check the value for “Intake air 4.8V
temperature sensor” using scan tool.
Is the “Intake air temperature sensor” more
than the specified value? Go to Step 7. Go to Step 6.
 Electronic control fuel injection system (Common rail type) 1E-297

Step Action Value YES NO

1. Check for followings in the signal circuit
between ECM and IAT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —

• Short circuit to IAT sensor ground

circuit
• Short circuit to ground
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 8.
Replace the IAT sensor.
7 —
Is the procedure completed? Go to Step 11. —
8 Is EMPS available? — Go to Step 9. Go to Step 10.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
9 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. Go to Step 10.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. —

1E-298 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
11 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0112 detected? Go to Step 3. Go to Step 12.
Check if other DTC is detected.
12 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine.
2. Check the display of intake
air 214°C (419°F)
13 temperature. (Displayed
Does the display of “Intake air temperature” error value) Go to “Diagnostic
show error value? Go to Step 14. aid”.
Check for installation condition of the IAT
sensor, ECM and coupling connector.
(Check the IAT sensor circuit for ground short.)
1. Check for play or looseness in the
14 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 15.
1. Check for followings in the signal circuit
between ECM and IAT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
15 board check procedure for sensors”. —

• Short circuit to IAT sensor ground

circuit
• Short circuit to ground
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 7.
 Electronic control fuel injection system (Common rail type) 1E-299
About IAT sensor Characteristics of intake air temperature sensor
The output voltage of IAT sensor changes according to
the intake air.
The scan tool with CAN communication displays a fixed
value when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value if
the value of −40°C (−40°F) or 120°C (248°F) is not
changed.
When error occurs, error value (214°C {419°F}) is
displayed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
Tech 2 and scan tools with KW communication can
display both voltage and physical value.

(V)
4.8691

Name
1. Signal
2. GND

0.1797
-40 120
(-40) (248) F
TSWG0180

1000

100

10
Resistance

0.1

0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
1E-300 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

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Resistance • Disconnect the 72 - 60 10 MΩ or 100Ω or
ground circuit/ measurement sensor 72 - Ground more less
ground connector.
• Key switch “OFF”

On-board check procedure for sensors Name

1. Coupling connector between engine — the
3 machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
2 1
harness. Check from step 1 again.
4 • If only step 1 is faulty, replace the sensor.

TSWG0197
 Electronic control fuel injection system (Common rail type) 1E-301
DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open
circuit or short to power supply circuit)

A A Engine control
module (ECM)

Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V

Vcc

37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Machine
control unit

CAN HIGH CAN LOW

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

6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor

TSHK0029

Description of circuit Preconditions when DTC is set

The intake air temperature (IAT) sensor is the • Key switch input voltage is 18V or more.
thermistor type and the value of resistance changes • DTC P1630 or P1632 is not detected.
according to the temperature. The resistance is low • 3 minutes or more has elapsed after starting
when the intake air temperature is high, and is high engine.
when the temperature is low. The ECM energizes 5 V to
the IAT sensor through the pull up resistance, and DTC set condition
calculate the intake air temperature from the change in
voltage, to utilize various control such as fuel injection • IAT sensor voltage is 4.95V or more for 4 seconds
control. If the resistance is low (temperature is high), or more.
the voltage becomes low; if the resistance is high
(temperature is low), the voltage becomes high. Action taken when DTC is set
• Trouble is displayed on the monitor of the
Main trouble symptom machine* or diagnosis lamp comes on. (* Nothing
• White smoke emission possible when starting at is displayed depending on the machine
low temperatures manufacturer)
1E-302 Electronic control fuel injection system (Common rail type)
Back-up mode • Worn harness cladding
• Intake air temperature default setting • Wire disconnection inside harness cladding
• (at starting: −10°C {14°F}, at running: 25°C {77°F}) Following inspections are necessary to detect these
causes.
• EGR stopped
• Improper connection of harness connector and
Recovery from failure ECM connector
– Poor connection of terminal from connector
Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from – Unmatched terminals are fitted.
failure. – Damage of connector lock
– Poor contact between terminal and wire
The conditions to clear the MIL/DTC • Damaged harness
• The present trouble turns to history trouble when – Visually check the harness for damage.
the condition is out of the range from DTC set – Check the relevant items on the scan tool data
condition (recovery from failure). display while moving the connector and the
• Using the scan tool, or memory clear switch and harness which are related to the sensor. The
diagnostic switch operation enables to clear DTCs. variation of the display indicates the faulty part.

Diagnostic aid Test description

• To make sure the correct performance of the IAT Numbers below indicate step numbers in the chart.
sensor, check with various temperatures using the 3. In case of present trouble, the “Intake air
reckoner table between temperature and temperature sensor” displays more than the specified
resistance. If the sensor is faulty, operationality value. In this case, identify the cause by referring to
may be affected. “Diagnostic aid”.
If the intermittent trouble is suspected, followings may 5. If the “Intake air temperature sensor” displays less
be the cause. than the specified value when terminals between the
• Improper connection of harness connector IAT sensor connector are shorted, the circuit beyond
• Defective harness routing the sensor is normal including ECM.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 15.
Check the value for IAT sensor using scan tool.
1. Connect the scan tool.
2. Start the engine.
3 3. Check the value for “Intake air 4.95V
temperature sensor” using scan tool.
Is the “Intake air temperature sensor” more Go to “Diagnostic
than the specified value? Go to Step 4. aid”.
Check for installation condition of the IAT
sensor, ECM and coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 5.
 Electronic control fuel injection system (Common rail type) 1E-303

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the IAT sensor connector.
3. Short the IAT sensor connector signal
terminal to the ground terminal using jump
cable.
5 4. Turn the key switch to “ON”. 0V
5. Check the value for “Intake air
temperature sensor” using scan tool.
Is the “Intake air temperature sensor” less than
the specified value? Go to Step 9. Go to Step 6.
1. Check the signal circuit between ECM and
IAT sensor for short circuit to the power
supply circuit or ignition power supply
circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —

Important:
If the IAT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 13. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and IAT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 8.
1E-304 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for followings in the ground circuit
between ECM and IAT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
8 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 10.
Replace the IAT sensor.
9 —
Is the procedure completed? Go to Step 13. —
10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 12.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
13 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0113 detected? Go to Step 2. Go to Step 14.
 Electronic control fuel injection system (Common rail type) 1E-305

Step Action Value YES NO

Check if other DTC is detected.
14 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine.
2. Check the display of intake air
temperature.
Display of intake air temperature is 214°C 214°C (419°F)
15 (419°F) due to back-up mode after fault (Displayed
judgment. error value)

Does the display of “Intake air temperature” Go to “Diagnostic

show error value? Go to Step 16. aid”.
Check for installation condition of the IAT
sensor, ECM and coupling connector.
1. Check for play or looseness in the
16 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 17.
1. Check the signal circuit between ECM and
IAT sensor for short circuit to the power
supply circuit or ignition power supply
circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
17 board check procedure for sensors”. —

Important:
If the IAT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 13. Go to Step 18.
1. Check for followings in the signal circuit
between ECM and IAT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
18 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 19.
1E-306 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for followings in the ground circuit
between ECM and IAT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
19 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 9.

About IAT sensor Characteristics of intake air temperature sensor

The output voltage of IAT sensor changes according to
the intake air.
The scan tool with CAN communication displays a fixed
value when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value if
the value of −40°C (−40°F) or 120°C (248°F) is not
changed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
Tech 2 and scan tools with KW communication can
display both voltage and physical value.

(V)
4.8691

Name
1. Signal
2. GND

0.1797
-40 120
(-40) (248) F
TSWG0180
 Electronic control fuel injection system (Common rail type) 1E-307

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

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
1E-308 Electronic control fuel injection system (Common rail type)

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Voltage • Disconnect the 72 - Ground 0V 18V or
power supply measurement sensor more
circuit connector.
• Key switch “ON”
7 Open circuit/ Resistance • Disconnect the 72 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector signal less more
resistance connector. terminal
• Key switch “OFF”
8 Open circuit/ Resistance • Disconnect the 60 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector ground less more
resistance connector. terminal
• Key switch “OFF”

On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
 Electronic control fuel injection system (Common rail type) 1E-309
DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault,
GND short, short circuit)

Vehicle speed Engine oil pressure

sensor signal 5V 5V sensor signal
5V

CKP CKP Engine coolant

Fuel temperature Vcc
HIGH LOW temperature sensor
signal signal sensor signal signal

108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56

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

3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

2 E-98 1 E-98

Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R

37 E-57 18 E-57
4 H-6

Vehicle
speed sensor A

Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor

TSHK0030

Description of circuit Main trouble symptom

The engine coolant temperature (ECT) sensor detects • Deterioration of startability at low temperatures
the engine coolant temperature. The ECT sensor is • Black smoke emitted
installed near the thermostat housing. The ECT sensor • Output lowering depending on conditions
is the thermistor type and the value of resistance inside
the sensor changes according to the temperature. If the Preconditions when DTC is set
temperature is high, the resistance becomes low; if the
• Key switch input voltage is 18V or more.
temperature is low, the resistance becomes high. The
engine control module (ECM) is connected to the ECT • DTC P1630 or P1633 is not detected.
sensor via signal circuit and ground circuit, and
energizes +5 V power supply to the signal circuit. ECM DTC set condition
recognizes the applied voltage, which varies with • ECT sensor voltage is 0.1V or less for 4 seconds
change in the resistance of ECT sensor according to or more.
temperature (If the temperature is high, the voltage
becomes low; if the temperature is low, the voltage
becomes high), as an input signal.
1E-310 Electronic control fuel injection system (Common rail type)
Action taken when DTC is set If the intermittent trouble is suspected, followings may
• Trouble is displayed on the monitor of the be the cause.
machine* or diagnosis lamp comes on. (* Nothing • Improper connection of harness connector
is displayed depending on the machine • Defective harness routing
manufacturer) • Worn harness cladding
• Wire disconnection inside harness cladding
Back-up mode Following inspections are necessary to detect these
• Coolant temperature default setting causes.
• (at starting: −20°C {4°F}, at running: 80°C {176°F}) • Improper connection of harness connector and
• EGR stopped ECM connector
– Poor connection of terminal from connector
Recovery from failure – Unmatched terminals are fitted.
Refer to “List of diagnostic trouble code” and “About – Damage of connector lock
recovery from failure” in this section for recovery from – Poor contact between terminal and wire
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
the condition is out of the range from DTC set harness which are related to the sensor. The
condition (recovery from failure). variation of the display indicates the faulty part.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs. Test description
Numbers below indicate step numbers in the chart.
Diagnostic aid
3. In case of present trouble, the “Engine coolant
• DTC may be set at a overheat condition. temperature sensor” displays more than the specified
• After starting the engine, the thermostat begins to value. In this case, identify the cause by referring to
open when the engine coolant temperature rises “Diagnostic aid”.
(4H: 85°C {185°F}, 6H: 82°C {180°F}), and the 5. If the “Engine coolant temperature sensor” displays
engine coolant temperature is stabilized. more than the specified value when the ECT sensor
• To make sure the correct performance of the ECT connector is removed, the circuit beyond the sensor is
sensor, check with various temperatures using the normal including ECM.
reckoner table between temperature and
resistance. If the sensor is faulty, operationality
may be affected.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed? Go to Step 2. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 13.
Check the value for ECT sensor using scan
tool.
1. Connect the scan tool.
2. Start the engine.
3 0.1V
3. Check the value for “Engine coolant
temperature sensor” using scan tool.
Is the “Engine coolant temperature sensor” Go to “Diagnostic
less than the specified value? Go to Step 4. aid”.
 Electronic control fuel injection system (Common rail type) 1E-311

Step Action Value YES NO

Check for installation condition of the ECT
sensor, ECM and coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 6.
1. Turn the key switch to “OFF”.
2. Disconnect the ECT sensor connector.
3. Turn the key switch to “ON”.
5 4. Check the value for “Engine coolant 4.8V
temperature sensor” using scan tool.
Is the “Engine coolant temperature sensor”
more than the specified value? Go to Step 7. Go to Step 6.
1. Check for followings in the signal circuit
between ECM and ECT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
6 • Short circuit to ECT sensor ground —
circuit
• Short circuit to ground
2. Measure the resistance of ECT sensor,
and check if the measured value is within
the normal range.
3. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 8.
Replace the ECT sensor.
7 —
Is the procedure completed? Go to Step 11. —
8 Is EMPS available? — Go to Step 9. Go to Step 10.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

9 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. Go to Step 10.

1E-312 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
11 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0117 detected? Go to Step 2. Go to Step 12.
Check if other DTC is detected.
12 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine.
2. Check the display of the engine coolant
temperature.
Display of engine coolant temperature is 214°C (419°F)
13 214°C (419°F) due to back-up mode after (Displayed
fault judgment. error value)

Does the display of “Engine coolant

temperature” show error value? Go to Step 11. Go to Step 14.
Check for installation condition of the ECT
sensor, ECM and coupling connector.
1. Check for play or looseness in the
14 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the procedure completed? — Go to Step 15.
 Electronic control fuel injection system (Common rail type) 1E-313

Step Action Value YES NO

1. Check for followings in the signal circuit
between ECM and ECT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
15 • Short circuit to ECT sensor ground —
circuit
• Short circuit to ground
2. Measure the resistance of ECT sensor,
and check if the measured value is within
the normal range.
3. If the trouble is detected, repair or replace
as required.
Is the procedure completed? — Go to Step 7.

About ECT sensor

2 1

1 2 3

TSWG0061

Name
1. Sensor ground (for engine control)
2. Sensor signal (for engine control)
3. Sensor signal (for meter)
1E-314 Electronic control fuel injection system (Common rail type)
Characteristics of ECT sensor Breaker box inspection procedure
The output voltage of ECT sensor changes according Perform the inspection in the following procedure if
to the engine coolant temperature. The scan tool with there is such an instruction to use breaker box in the
CAN communication displays a fixed value when the step. After inspection, return to the diagnostic step.
value exceeds the threshold voltage. Therefore, judge
as it is more than the threshold value if the value of −
40°C (−40°F) or 120°C (248°F) is not changed.
When error occurs, error value (214°C {419°F}) is
displayed.
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
display both voltage and physical value.

(V)
4.8691

Name
1. Breaker box
2. DMM

0.1797
-40 120
(-40) (248) F
TSWG0180
 Electronic control fuel injection system (Common rail type) 1E-315

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Resistance • Disconnect the 84 - 79 10 MΩ or 100Ω or
ground circuit/ measurement sensor 84 - Ground more less
ground connector.
• Key switch “OFF”

On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
1E-316 Electronic control fuel injection system (Common rail type)
DTC: P0118 (Flash code 23) Engine coolant temperature sensor input is high (open circuit
or short to power supply)
(*: Specifications vary depending on each machine. Refer to the machine’s manual.)

Vehicle speed Engine oil pressure

sensor signal 5V 5V sensor signal
5V

CKP CKP Engine coolant

Fuel temperature Vcc
HIGH LOW temperature sensor
signal signal sensor signal signal

108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56

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

3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

2 E-98 1 E-98

Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R

37 E-57 18 E-57
4 H-6

Vehicle
speed sensor A

Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor

TSHK0030

Description of circuit Main trouble symptom

The engine coolant temperature (ECT) sensor detects • Noise deteriorates.
the engine coolant temperature. The ECT sensor is • White smoke emitted at low temperatures.
installed near the thermostat housing. The ECT sensor • Rough idling
is the thermistor type and the value of resistance inside
the sensor changes according to the temperature. If the Preconditions when DTC is set
temperature is high, the resistance becomes low; if the
temperature is low, the resistance becomes high. The • Key switch input voltage is 18V or more.
engine control module (ECM) is connected to the ECT • DTC P1630 or P1633 is not detected.
sensor via signal circuit and ground circuit, and • 3 minutes or more has elapsed after starting
energizes +5 V power supply to the signal circuit. ECM engine.
recognizes the applied voltage, which varies with
change in the resistance of ECT sensor according to DTC set condition
temperature (If the temperature is high, the voltage • ECT sensor voltage is 4.85V or more for 4 seconds
becomes low; if the temperature is low, the voltage or more.
becomes high), as an input signal.
 Electronic control fuel injection system (Common rail type) 1E-317
Action taken when DTC is set If the intermittent trouble is suspected, followings may
• Trouble is displayed on the monitor of the be the cause.
machine* or diagnosis lamp comes on. (* Nothing • Improper connection of harness connector
is displayed depending on the machine • Defective harness routing
manufacturer) • Worn harness cladding
• Wire disconnection inside harness cladding
Back-up mode Following inspections are necessary to detect these
• Coolant temperature default setting causes.
• (at starting: −20°C {−4°F}, at running: 80°C • Improper connection of harness connector and
{176°F}) ECM connector
• EGR stopped – Poor connection of terminal from connector
– Unmatched terminals are fitted.
Recovery from failure – Damage of connector lock
Refer to “List of diagnostic trouble code” and “About – Poor contact between terminal and wire
recovery from failure” in this section for recovery from • Damaged harness
failure.
– Visually check the harness for damage.
The conditions to clear the MIL/DTC – Check the relevant items on the scan tool data
display while moving the connector and the
• The present trouble turns to history trouble when harness which are related to the sensor. The
the condition is out of the range from DTC set variation of the display indicates the faulty part.
condition (recovery from failure).
• Using the scan tool, or memory clear switch and Test description
diagnostic switch operation enables to clear DTCs.
Numbers below indicate step numbers in the chart.
3. In case of present trouble, the “Engine coolant
Diagnostic aid
temperature sensor” displays more than the specified
• After starting the engine, the thermostat begins to value. If less than the specified value, identify the cause
open when the engine coolant temperature rises by referring to “Diagnostic aid”.
(4H: 85°C {185°F}, 6H: 82°C {180°F}), and the 5. If the “Engine coolant temperature sensor” displays
engine coolant temperature is stabilized. less than the specified value when terminals between
• To make sure the correct performance of the ECT the ECT sensor connector are shorted, the circuit
sensor, check with various temperatures using the beyond the sensor is normal including ECM.
reckoner table between temperature and
resistance. If the sensor is faulty, operationality
may be affected.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 15.
Check the value for ECT sensor using scan
tool.
1. Connect the scan tool.
2. Start the engine.
3 4.85V
3. Check the value for “Engine coolant
temperature sensor” using scan tool.
Is the “Engine coolant temperature sensor” Go to “Diagnostic
more than the specified value? Go to Step 4. aid”.
1E-318 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check for installation condition of the ECT
sensor, ECM and coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 5.
1. Turn the key switch to “OFF”.
2. Disconnect the ECT sensor connector.
3. Short the ECT sensor connector signal
terminal to the ground terminal using jump
cable.
5 4. Turn the key switch to “ON”. 0V
5. Check the value for “Engine coolant
temperature sensor” using scan tool.
Is the “Engine coolant temperature sensor”
less than the specified value? Go to Step 9. Go to Step 6.
1. Check the signal circuit between ECM and
ECT sensor for short circuit to the power
supply circuit or ignition power supply
circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
Important:
If the ECT sensor circuit is shorted to the
power supply circuit, the sensor may be
broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 13. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and ECT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 8.
 Electronic control fuel injection system (Common rail type) 1E-319

Step Action Value YES NO

1. Check for followings in the ground circuit
between ECM and ECT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
8 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 10.
Replace the ECT sensor.
9 —
Is the procedure completed? Go to Step 13. —
10 Is EMPS available? — Go to Step 10. Go to Step 11.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 11.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
13 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0118 detected? Go to Step 2. Go to Step 14.
1E-320 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check if other DTC is detected.
14 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine.
2. Check the display of the “Engine coolant
temperature”.
Display of engine coolant temperature is 214°C (419°F)
15 214°C (419°F) due to back-up mode after (Displayed
fault judgment. error value)

Does the display of “Engine coolant Go to “Diagnostic

temperature” show error value? Go to Step 16. aid”.
Check for installation condition of the ECT
sensor, ECM and coupling connector.
1. Check for play or looseness in the
16 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 17.
1. Check the signal circuit between ECM and
ECT sensor for short circuit to the power
supply circuit or ignition power supply
circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
17 board check procedure for sensors”. —
Important:
If the ECT sensor circuit is shorted to the
power supply circuit, the sensor may be
broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 13. Go to Step 18.
1. Check for followings in the signal circuit
between ECM and ECT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
18 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 19.
 Electronic control fuel injection system (Common rail type) 1E-321

Step Action Value YES NO

1. Check for followings in the ground circuit
between ECM and ECT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
19 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 9.

About ECT sensor Characteristics of ECT sensor

The output voltage of ECT sensor changes according
to the engine coolant temperature. The scan tool with
2 1 CAN communication displays a fixed value when the
value exceeds the threshold voltage. Therefore, judge
as it is more than the threshold value if the value of −
40°C (−40°F) or 120°C (248°F) is displayed.
When error occurs, error value (214°C {419°F}) is
displayed.
The following illustration shows the correlation between
3
physical value and voltage displayed in the scan tools
with CAN communication.
1 2 3 Tech2 and scan tools with KW communication can
display both voltage and physical value.

(V)

TSWG0061 4.7441

Name
1. Sensor GND (for engine control)
2. Sensor signal (for engine control)
3. Sensor signal (for meter)

0.2129

-40 120
(-40) (248) F
TSWG0181
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

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Voltage • Disconnect the 84 - Ground 0V 18V or
power supply measurement sensor more
circuit connector.
• Key switch “ON”
7 Open circuit/ Resistance • Disconnect the 84 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector signal less more
resistance connector. terminal
• Key switch “OFF”
8 Open circuit/ Resistance • Disconnect the 79 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector ground less more
resistance connector. terminal
• Key switch “OFF”
 Electronic control fuel injection system (Common rail type) 1E-323
On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
1E-324 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.)

Vehicle speed Engine oil pressure

sensor signal 5V 5V sensor signal
5V

CKP CKP Engine coolant

Fuel temperature Vcc
HIGH LOW temperature sensor
signal signal sensor signal signal

108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56

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

3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

2 E-98 1 E-98

Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R

37 E-57 18 E-57
4 H-6

Vehicle
speed sensor A

Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor

TSHK0030

Description of circuit Preconditions when DTC is set

The fuel temperature (FT) sensor is the thermistor type • Key switch input voltage is 18V or more.
and the value of resistance changes according to the • DTC P1630 or P1633 is not detected.
temperature. The fuel temperature (FT) sensor is
installed near the fuel inlet duct in the supply pump. The DTC set condition
resistance is low when the fuel temperature is high, and
• FT sensor voltage is 0.1V or less for 4 seconds or
is high when the temperature is low. The ECM
more.
energizes 5 V to the FT sensor through the pull up
resistance, and calculates the fuel temperature from
Action taken when DTC is set
the change in voltage, to utilize for supply control etc. If
the resistance is low (temperature is high), the voltage • Trouble is displayed on the monitor of the
becomes low; if the resistance is high (temperature is machine* or diagnosis lamp comes on. (* Nothing
low), the voltage becomes high. is displayed depending on the machine
manufacturer)
Main trouble symptom
Operationality is affected.
 Electronic control fuel injection system (Common rail type) 1E-325
Back-up mode • Worn harness cladding
• Fuel temperature default setting • Wire disconnection inside harness cladding
(at starting: −20°C {−4°F}, at running: 70°C Following inspections are necessary to detect these
{158°F}) causes.
• Improper connection of harness connector and
Recovery from failure ECM connector
Refer to “List of diagnostic trouble code” and “About – Poor connection of terminal from connector
recovery from failure” in this section for recovery from – Unmatched terminals are fitted.
failure. – Damage of connector lock
– Poor contact between terminal and wire
The conditions to clear the MIL/DTC
• Damaged harness
• The present trouble turns to history trouble when – Visually check the harness for damage.
the condition is out of the range from DTC set
– Check the relevant items on the scan tool data
condition (recovery from failure).
display while moving the connector and the
• Using the scan tool, or memory clear switch and harness which are related to the sensor. The
diagnostic switch operation enables to clear DTCs. variation of the display indicates the faulty part.

Diagnostic aid Test description

• When the engine cold (before starting engine), Numbers below indicate step numbers in the chart.
check if the temperatures of the FT sensor and IAT 3. In the case of present trouble, the “Fuel temperature
sensor are close. sensor” displays more than the specified value. In this
If the intermittent trouble is suspected, followings may case, identify the cause by referring to “Diagnostic aid”.
be the cause. 5. If the “Fuel temperature sensor” displays more than
• Improper connection of harness connector the specified value when the FT sensor connector is
• Defective harness routing removed, the circuit beyond the sensor is normal
including ECM.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 13.
Check the value for FT sensor using scan tool.
1. Connect the scan tool.
2. Start the engine.
3 3. Check the value for “Fuel temperature 0.1V
sensor” using scan tool.
Is the “Fuel temperature sensor” less than the Go to “Diagnostic
specified value? Go to Step 4. aid”.
Check for installation condition of the FT
sensor, ECM and coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 5.
1. Turn the key switch to “OFF”.
2. Disconnect the FT sensor connector.
3. Turn the key switch to “ON”.
5 4. Check the value for “Fuel temperature 4.8V
sensor” using scan tool.
Is the “Fuel temperature sensor” more than the
specified value? Go to Step 7. Go to Step 6.
1E-326 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for followings in the signal circuit
between ECM and FT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 —
board check procedure for sensors”.

• Short circuit to FT sensor ground circuit

• Short circuit to ground
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 8.
Replace the supply pump (FT sensor).
7 —
Is the procedure completed? Go to Step 11. —
8 Is EMPS available? — Go to Step 9. Go to Step 10.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
9 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. Go to Step 10.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
11 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0182 detected? Go to Step 2. Go to Step 12.
 Electronic control fuel injection system (Common rail type) 1E-327

Step Action Value YES NO

Check if other DTC is detected.
12 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine.
2. Check the display of “Fuel temperature”.
Display of fuel temperature is 214°C 214°C (419°F)
13 (419°F) due to back-up mode after fault (Displayed
judgment. error value)
Does the display of “Fuel temperature” show Go to “Diagnostic
error value? Go to Step 14. aid”.
Check for installation condition of the FT
sensor, ECM and coupling connector.
1. Check for play or looseness in the
14 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 15.
1. Check for followings in the signal circuit
between ECM and FT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
15 —
board check procedure for sensors”.

• Short circuit to FT sensor ground circuit

• Short circuit to ground
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 6.

About FT sensor Name

1. GND
2. Signal
1E-328 Electronic control fuel injection system (Common rail type)
Characteristics of FT sensor
The output voltage of FT sensor changes according to
the fuel temperature. The scan tool with CAN
communication displays a fixed value when the value 25
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. 20
When error occurs, error value (214°C {419°F}) is
displayed. 15
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
10
with CAN communication.
Tech2 and scan tools with KW communication can
display both voltage and physical value. 5

-30 0 30 60 90 120
(V) (-22) (32) (86) (140) (194) (248) F
TSWG0210

4.5195
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.

0.1973

-30 120
(-22) (248) F
TSWG0203

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Resistance • Disconnect the 83 - 109 10 MΩ or 100Ω or
ground circuit/ measurement sensor 83 - Ground more less
ground connector.
• Key switch “OFF”
 Electronic control fuel injection system (Common rail type) 1E-329
On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
1E-330 Electronic control fuel injection system (Common rail type)
DTC: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open circuit
or short to power supply circuit)
(*: Specifications vary depending on each machine. Refer to the machine’s manual.)

Vehicle speed Engine oil pressure

sensor signal 5V 5V sensor signal
5V

CKP CKP Engine coolant

Fuel temperature Vcc
HIGH LOW temperature sensor
signal signal sensor signal signal

108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56

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

3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

2 E-98 1 E-98

Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R

37 E-57 18 E-57
4 H-6

Vehicle
speed sensor A

Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor

TSHK0030

Description of circuit Preconditions when DTC is set

The fuel temperature (FT) sensor is the thermistor type • Key switch input voltage is 18V or more.
and the value of resistance changes according to the • DTC P1630 or P1633 is not detected.
temperature. The fuel temperature (FT) sensor is • 3 minutes or more has elapsed after starting
installed near the fuel inlet duct in the supply pump. The engine.
resistance is low when the fuel temperature is high, and
is high when the temperature is low. The ECM DTC set condition
energizes 5 V to the FT sensor through the pull up
resistance, and calculates the fuel temperature from • FT sensor voltage is 4.85V or more for 4 seconds
the change in voltage, to utilize for supply control etc. If or more.
the resistance is low (temperature is high), the voltage
becomes low; if the resistance is high (temperature is Action taken when DTC is set
low), the voltage becomes high. • Trouble is displayed on the monitor of the
machine* or diagnosis lamp comes on. (* Nothing
Main trouble symptom is displayed depending on the machine
Not in particular manufacturer)
 Electronic control fuel injection system (Common rail type) 1E-331
Back-up mode • Worn harness cladding
• Fuel temperature default setting • Wire disconnection inside harness cladding
(at starting: −20°C {−4°F}, at running: 70°C Following inspections are necessary to detect these
{158°F}) causes.
• Improper connection of harness connector and
Recovery from failure ECM connector
Refer to “List of diagnostic trouble code” and “About – Poor connection of terminal from connector
recovery from failure” in this section for recovery from – Unmatched terminals are fitted.
failure. – Damage of connector lock
– Poor contact between terminal and wire
The conditions to clear the MIL/DTC
• Damaged harness
• The present trouble turns to history trouble when – Visually check the harness for damage.
the condition is out of the range from DTC set
– Check the relevant items on the scan tool data
condition (recovery from failure).
display while moving the connector and the
• Using the scan tool, or memory clear switch and harness which are related to the sensor. The
diagnostic switch operation enables to clear DTCs. variation of the display indicates the faulty part.

Diagnostic aid Test description

• When the engine cold (before starting engine), Numbers below indicate step numbers in the chart.
check if the temperatures of the FT sensor and IAT 3. In the case of present trouble, the “Fuel temperature
sensor are close. sensor” displays more than the specified value. In this
If the intermittent trouble is suspected, followings may case, identify the cause by referring to “Diagnostic aid”.
be the cause. 5. If the “Fuel temperature sensor” displays less than
• Improper connection of harness connector the specified value when terminals between the FT
• Defective harness routing sensor connector are shorted, the circuit beyond the
sensor is normal including ECM.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 15.
Check the value for FT sensor using scan tool.
1. Connect the scan tool.
2. Start the engine.
3 3. Check the value for “Fuel temperature 4.85V
sensor” using scan tool.
Is the “Fuel temperature sensor” more than the Go to “Diagnostic
specified value? Go to Step 4. aid”.
Check for installation condition of the FT
sensor, ECM and coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 5.
1E-332 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the FT sensor connector.
3. Short the FT sensor connector signal
terminal to the ground terminal using jump
cable.
5 4. Turn the key switch to “ON”. 0V
5. Check the value for “Fuel temperature
sensor” using scan tool.
Is the “Fuel temperature sensor” less than the
specified value? Go to Step 9. Go to Step 6.
1. Check the signal circuit between ECM and
FT sensor for short circuit to the power
supply circuit or ignition power supply
circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —

Important:
If the FT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 13. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and FT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 8.
 Electronic control fuel injection system (Common rail type) 1E-333

Step Action Value YES NO

1. Check for followings in the ground circuit
between ECM and FT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
8 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 10.
Replace the supply pump (FT sensor).
9 —
Is the procedure completed? Go to Step 13. —
10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 12.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
13 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0183 detected? Go to Step 2. Go to Step 14.
1E-334 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check if other DTC is detected.
14 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine.
2. Check the display of “Fuel temperature”.
Display of fuel temperature is 214°C 214°C (419°F)
15 (419°F) due to back-up mode after fault (Displayed
judgment. error value)
Does the display of “Fuel temperature” show Go to “Diagnostic
error value? Go to Step 16. aid”.
Check for installation condition of the FT
sensor, ECM and coupling connector.
1. Check for play or looseness in the
16 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 17.
1. Check the signal circuit between ECM and
FT sensor for short circuit to the power
supply circuit or ignition power supply
circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
17 board check procedure for sensors”. —

Important:
If the FT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 13. Go to Step 18.
1. Check for followings in the signal circuit
between ECM and FT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
18 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 19.
 Electronic control fuel injection system (Common rail type) 1E-335

Step Action Value YES NO

1. Check for followings in the ground circuit
between ECM and FT sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
19 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 9.

About FT sensor Characteristics of FT sensor

The output voltage of FT sensor changes according to
the fuel temperature. The scan tool with CAN
communication displays a fixed value when the value
exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value if
the value of −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
display both voltage and physical value.

(V)

4.5195

Name
1. GND
2. Signal

0.1973

-30 120
(-22) (248) F
TSWG0203
1E-336 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
25
step. After inspection, return to the diagnostic step.

20

15

10

-30 0 30 60 90 120
(-22) (32) (86) (140) (194) (248) F
TSWG0210

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Voltage • Disconnect the 83 - Ground 0V 18V or
power supply measurement sensor more
circuit connector.
• Key switch “ON”
7 Open circuit/ Resistance • Disconnect the 83 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector signal less more
resistance connector. terminal
• Key switch “OFF”
8 Open circuit/ Resistance • Disconnect the 109 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector ground less more
resistance connector. terminal
• Key switch “OFF”
 Electronic control fuel injection system (Common rail type) 1E-337
On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
1E-338 Electronic control fuel injection system (Common rail type)
DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short
circuit)

Engine control
module (ECM)

CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V

B+ B+ B+

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

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

0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B

1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W

1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 W

V U

EGR position sensor/EGR motor

EGR valve

CMP sensor Common rail pressure sensor

TSHK0028

Description of circuit Main trouble symptom

The common rail pressure sensor detects the common • Engine blow up
rail internal pressure. The common rail pressure sensor • Hunting
is installed to the common rail. As the common rail
internal pressure changes depending on engine Preconditions when DTC is set
condition, output voltage of the common rail pressure
• Key switch input voltage is 18V or more.
sensor will change (if the common rail internal fuel
pressure is low, output voltage becomes low, if the • DTC P1630 or P1635 is not detected.
pressure is high, the output voltage becomes high as
well). The engine control module (ECM) reads this DTC set condition
output voltage change, converting it into common rail • Common rail pressure sensor voltage becomes
internal pressure, to utilize for control. Dedicated 0.7V or less.
communication circuits are used for the sensor power
supply (5V), SIG, and ground in the common rail Action taken when DTC is set
pressure sensor, which are connected to the ECM. • Trouble is displayed on the monitor of the
Also, the sensor circuit is shielded to avoid electrical machine* or diagnosis lamp comes on. (* Nothing
noise etc. is displayed depending on the machine
manufacturer)
 Electronic control fuel injection system (Common rail type) 1E-339
Back-up mode • Wire disconnection inside harness cladding
• Specified back-up value (depending on the Following inspections are necessary to detect these
machine manufacturer) causes.
• Improper connection of harness connector and
Recovery from failure ECM connector
Refer to “List of diagnostic trouble code” and “About – Poor connection of terminal from connector
recovery from failure” in this section for recovery from – Unmatched terminals are fitted.
failure. – Damage of connector lock
– Poor contact between terminal and wire
The conditions to clear the MIL/DTC • Damaged harness
• The present trouble turns to history trouble when – Visually check the harness for damage.
the condition is out of the range from DTC set – Check the relevant items on the scan tool data
condition (recovery from failure). display while moving the connector and the
• The diagnosis lamp will go off after the code turns harness which are related to the sensor. The
to history trouble and the key switch is turned variation of the display indicates the faulty part.
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and Test description
diagnostic switch operation enables to clear DTCs. Numbers below indicate step numbers in the chart.
3. In the case of present trouble, the “Common rail
Diagnostic aid pressure sensor” displays more than the specified
If the intermittent trouble is suspected, followings may value. If more than the specified value, identify the
be the cause. cause by referring to “Diagnostic aid”.
• Improper connection of harness connector 5. If the “Common rail pressure sensor” displays more
• Defective harness routing than the specified value when the common rail
pressure sensor connector is removed, the circuit
• Worn harness cladding
beyond the sensor is normal including ECM.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 14.
Check the value for common rail pressure
sensor using scan tool.
1. Connect the scan tool.
2. Start the engine. 0.7V
3
3. Check the value for “Common rail (at idle)
pressure sensor” using scan tool.
Is the “Common rail pressure sensor” output Go to “Diagnostic
voltage less than the specified value? Go to Step 4. aid”.
Check for installation condition of the common
rail pressure sensor, ECM and coupling
connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 5.
1E-340 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Turn the key switch to “ON”.
5 0V
4. Check the value for “Common rail
pressure sensor” using scan tool.
Is the “Common rail pressure sensor” output
voltage specified value? Go to Step 8. Go to Step 6.
1. Check for followings in the power supply
circuit between ECM and common rail
pressure sensor using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.

Note:
6 If breaker box is not available, refer to “On- —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and common rail pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
7 board check procedure for sensors”. —

• Short circuit to common rail pressure

sensor ground circuit
• Short circuit to ground
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the common rail (common rail
pressure sensor).

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

Is the procedure completed? Go to Step 12. —

9 Is EMPS available? — Go to Step 10. Go to Step 11.
 Electronic control fuel injection system (Common rail type) 1E-341

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

10 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. Go to Step 11.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
12 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0192 detected? Go to Step 2. Go to Step 13.
Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
Check for installation condition of the common
rail pressure sensor, ECM and coupling
connector.
1. Check for play or looseness in the
14 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 12. Go to Step 15.
1E-342 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Turn the key switch to “ON”.
15 0V
4. Connect the DMM between the common
rail pressure sensor signal terminal and
the ground.
Does the DMM indicate the specified value? Go to Step 8. Go to Step 6.

About common rail pressure sensor Breaker box inspection procedure

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.

3 2 1

TSWG0055

Name
1. GND
2. Signal
3. Power supply Name
1. Breaker box
About common rail pressure sensor 2. DMM

(V)
4.2

0 200(29008)
MPa(psi)
TSWG0201
 Electronic control fuel injection system (Common rail type) 1E-343

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Open circuit/ Resistance • Disconnect the 87 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector power less more
resistance connector. supply terminal
• Key switch “OFF”
7 Short circuit to Resistance • Disconnect the 82 - 101 10 MΩ or 100Ω or
ground circuit/ measurement sensor 90 - 101 more less
ground connector. 82 - Ground
• Key switch “OFF” 90 - Ground
Open circuit/ Resistance • Disconnect the 82 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector signal less more
resistance connector. terminal
• Key switch “OFF” 90 - Sensor
connector signal
terminal

On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
1E-344 Electronic control fuel injection system (Common rail type)
DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault)

Engine control
module (ECM)

CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V

B+ B+ B+

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

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

0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B

1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W

1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 W

V U

EGR position sensor/EGR motor

EGR valve

CMP sensor Common rail pressure sensor

TSHK0028

Description of circuit Main trouble symptom

The common rail pressure sensor detects the common • Output lowering
rail internal pressure. The common rail pressure sensor • Engine stall possible
is installed to the common rail. As the common rail
internal pressure changes depending on engine Preconditions when DTC is set
condition, output voltage of the common rail pressure
• Key switch input voltage is 18V or more.
sensor will change (if the common rail internal fuel
pressure is low, output voltage becomes low, if the • DTC P1630 or P1635 is not detected.
pressure is high, the output voltage becomes high as
well). The engine control module (ECM) reads this DTC set condition
output voltage change, converting it into common rail • Common rail pressure sensor voltage becomes
internal pressure, to utilize for control. Dedicated 4.5V or more.
communication circuits are used for the sensor power
supply (5V), SIG, and ground in the common rail Action taken when DTC is set
pressure sensor, which are connected to the ECM. • Trouble is displayed on the monitor of the
Also, the sensor circuit is shielded to avoid electrical machine* or diagnosis lamp comes on. (* Nothing
noise etc. is displayed depending on the machine
manufacturer)
 Electronic control fuel injection system (Common rail type) 1E-345
Back-up mode • Wire disconnection inside harness cladding
• Specified back-up value (depending on the Following inspections are necessary to detect these
machine manufacturer) causes.
• Improper connection of harness connector and
Recovery from failure ECM connector
Refer to “List of diagnostic trouble code” and “About – Poor connection of terminal from connector
recovery from failure” in this section for recovery from – Unmatched terminals are fitted.
failure. – Damage of connector lock
– Poor contact between terminal and wire
The conditions to clear the MIL/DTC • Damaged harness
• The present trouble turns to history trouble when – Visually check the harness for damage.
the condition is out of the range from DTC set – Check the relevant items on the scan tool data
condition (recovery from failure). display while moving the connector and the
• The diagnosis lamp will go off after the code turns harness which are related to the sensor. The
to history trouble and the key switch is turned variation of the display indicates the faulty part.
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and Test description
diagnostic switch operation enables to clear DTCs. Numbers below indicate step numbers in the chart.
3. In the case of present trouble, the “Common rail
Diagnostic aid pressure sensor” displays more than the specified
If the intermittent trouble is suspected, followings may value. If more than the specified value, identify the
be the cause. cause by referring to “Diagnostic aid”.
• Improper connection of harness connector 5. If the “Common rail pressure sensor” displays less
• Defective harness routing than the specified value when terminals between the
common rail pressure sensor connector are shorted,
• Worn harness cladding
the circuit beyond the sensor is normal including ECM.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 15.
Check the value for common rail pressure
sensor using scan tool.
1. Connect the scan tool.
2. Start the engine.
3 4.5V
3. Check the value for “Common rail
pressure sensor” using scan tool.
Is the “Common rail pressure sensor” more Go to “Diagnostic
than the specified value? Go to Step 4. aid”.
Check for installation condition of the common
rail pressure sensor, ECM and coupling
connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 5.
1E-346 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Short the common rail pressure sensor
connector power supply terminal and the
5 signal terminal using jump cable. 4.8V
4. Turn the key switch to “ON”.
5. Check the value for “Common rail
pressure sensor” using scan tool.
Is the “Common rail pressure sensor” less than
the specified value? Go to Step 9. Go to Step 6.
1. Check the signal circuit between ECM and
common rail pressure sensor for short
circuit to the power supply circuit or
ignition power supply circuit using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —

Important:
If the common rail pressure sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 13. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and common rail pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 8.
 Electronic control fuel injection system (Common rail type) 1E-347

Step Action Value YES NO

1. Check for followings in the ground circuit
between ECM and common rail pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
8 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 10.
Replace the common rail (common rail
pressure sensor).

Note:
9 —
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? Go to Step 13. —

10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

11 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 12.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

1E-348 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
13 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0193 detected? Go to Step 2. Go to Step 14.
Check if other DTC is detected.
14 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
Check for installation condition of the common
rail pressure sensor, ECM and coupling
connector.
1. Check for play or looseness in the
15 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 16.
1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Turn the key switch to “ON”.
16 4. Connect the DMM between the common 4.8V
rail pressure sensor power supply terminal
and the signal terminal.
Is the DMM indication less than the specified
value? Go to Step 9. Go to Step 6.
 Electronic control fuel injection system (Common rail type) 1E-349
About common rail pressure sensor 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.

3 2 1

TSWG0055

Name
1. GND
2. Signal
3. Power supply Name
1. Breaker box
About common rail pressure sensor 2. DMM

(V)
4.2

0 200(29008)
MPa(psi)
TSWG0201
1E-350 Electronic control fuel injection system (Common rail type)

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

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

On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
 Electronic control fuel injection system (Common rail type) 1E-351
DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system
4HK1

2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

Injector Injector Injector Injector

(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)

3 3
3 E-35 3 E-37 E-27 E-31

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

R L/Y L/R R W L L/W W

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

Cylinder No. 3 Cylinder No. 2 Cylinder No. 1 Cylinder No. 4

Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSHK0031
1E-352 Electronic control fuel injection system (Common rail type)
6HK1

Injector Injector Injector Injector Injector Injector

(Cylinder No. 5) (Cylinder No. 6) (Cylinder No. 4) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 3)

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

3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

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

Feedback Feedback Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSWG0076

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
energizes 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-353
Cylinder No. and injection order Name
4HK1 1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6
6 7. Cylinder block
1 8. Engine front

Fuel injection is performed to each cylinder in the order

2 of 1 — 5 — 3 — 6 — 2 — 4.

5 3
Main trouble symptom
• Intense engine vibration
4
• Rough idling
• Output lowering
• Engine blow up fault

Preconditions when DTC is set

TSHK0032
• Main relay power supply voltage is 18V or more.
Name • 70 rpm or more
1. Cylinder No. 1 • DTC P0611, P1261, or P0201 is not detected.
2. Cylinder No. 2
3. Cylinder No. 3 DTC set condition
4. Cylinder No. 4
• Open/short circuit is detected in No. 1 cylinder
5. Cylinder block
injector drive circuit.
6. Engine front
• No. 1 cylinder injector monitor input signal does not
Fuel injection order is 1 — 3 — 4 — 2. exist for 2.4 seconds or more.
6HK1
Action taken when DTC is set
• Trouble is displayed on the monitor of the
machine* or diagnosis lamp comes on. (* Nothing
8
1 is displayed depending on the machine
manufacturer)
2
Back-up mode
• Injection for cylinder #1 stopped, EGR stopped
3

Recovery from failure

7
4 Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
5
failure.

The conditions to clear the MIL/DTC

6
• The present trouble turns to history trouble when
the condition is out of the range from DTC set
TSWG0157 condition (recovery from failure).
• The diagnosis lamp will go off after the code turns
to history trouble and the key switch is turned
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
1E-354 Electronic control fuel injection system (Common rail type)
Diagnostic aid – Poor connection of terminal from connector
If the intermittent trouble is suspected, followings may – Unmatched terminals are fitted.
be the cause. – Damage of connector lock
• Improper connection of harness connector – Poor contact between terminal and wire
• Defective harness routing • Damaged harness
• Worn harness cladding – Visually check the harness for damage.
• Wire disconnection inside harness cladding – Check the relevant items on the scan tool data
Following inspections are necessary to detect these display while moving the connector and the
causes. harness which are related to the sensor. The
• Improper connection of harness connector and variation of the display indicates the faulty part.
ECM connector

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Check the DTC.
1. Turn the key switch to “OFF” for more than
10 seconds.
2 2. Start the engine. —
3. Check the DTC.
Go to “Diagnostic
Is DTC detected? Go to Step 3. aid”.
1. Turn the key switch to “OFF”.
2. Remove the coupling connector (H−94)
from the cylinder head cover case.
3. Measure the resistance between the 0.45±0.1Ω
3 coupling connector terminals (power (20°C {68°F})
supply terminal — No. 1 cylinder injector
drive signal terminal).
Is the resistance less than the specified value? Go to Step 4. Go to Step 5.
1. Check for followings in the circuit between
ECM and coupling connector (H−94) using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for
5 looseness etc. —
3. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 6.
 Electronic control fuel injection system (Common rail type) 1E-355

Step Action Value YES NO

Check for installation condition of the coupling
connector.
1. Check for play or looseness in the
6 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 7.
1. Check for following in the circuit between
injector terminal and coupling connector.
• Open circuit
7 • High resistance —
2. If the trouble is detected, repair or replace
as required.
Is there any trouble in the circuit? Go to Step 13. Go to Step 9.
Check for installation condition of the ECM
connector.
1. Turn the key switch to “OFF”.
2. Remove the ECM.
8 3. Check for play or looseness in the —
connection.
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 10.
1. Replace the No. 1 cylinder injector.

Note:
9 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 13. —

10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 12.

1E-356 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
13 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0201 detected? Go to Step 2. Go to Step 14.
Check if other DTC is detected.
14 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM
 Electronic control fuel injection system (Common rail type) 1E-357

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
4 Open circuit/ Resistance • Remove the 119 - Coupling 100Ω or 10 MΩ or
high measurement coupling connector terminal less more
resistance connector. (H−94)
• Key switch “OFF” (4H: No. 5, 6H: No.
2)
1E-358 Electronic control fuel injection system (Common rail type)
DTC: P0202 (Flash code 272) Open circuit in injection nozzle #2 drive system
4HK1

2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

Injector Injector Injector Injector

(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)

3 3
3 E-35 3 E-37 E-27 E-31

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

R L/Y L/R R W L L/W W

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

Cylinder No. 3 Cylinder No. 2 Cylinder No. 1 Cylinder No. 4

Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSHK0031
 Electronic control fuel injection system (Common rail type) 1E-359
6HK1

Injector Injector Injector Injector Injector Injector

(Cylinder No. 5) (Cylinder No. 6) (Cylinder No. 4) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 3)

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

3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

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

Feedback Feedback Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSWG0076

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
energizes 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-360 Electronic control fuel injection system (Common rail type)
Cylinder No. and injection order Name
4HK1 1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6
6 7. Cylinder block
1 8. Engine front

Fuel injection is performed to each cylinder in the order

2 of 1 — 5 — 3 — 6 — 2 — 4.

5 3
Main trouble symptom
• Intense engine vibration
4
• Rough idling
• Output lowering
• Engine blow up fault

Preconditions when DTC is set

TSHK0032
• Main relay power supply voltage is 18V or more.
Name • 70 rpm or more
1. Cylinder No. 1 • DTC P0611, P1261, or P0202 is not detected.
2. Cylinder No. 2
3. Cylinder No. 3 DTC set condition
4. Cylinder No. 4
• Open/short circuit is detected in No. 2 cylinder
5. Cylinder block
injector drive circuit.
6. Engine front
• No. 2 cylinder injector monitor input signal does not
Fuel injection order is 1 — 3 — 4 — 2. exist for 2.4 seconds or more.
6HK1
Action taken when DTC is set
• Trouble is displayed on the monitor of the
machine* or diagnosis lamp comes on. (* Nothing
8
1 is displayed depending on the machine
manufacturer)
2
Back-up mode
• Injection for cylinder #2 stopped, EGR stopped
3

Recovery from failure

7
4 Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
5
failure.

The conditions to clear the MIL/DTC

6
• The present trouble turns to history trouble when
the condition is out of the range from DTC set
TSWG0157 condition (recovery from failure).
• The diagnosis lamp will go off after the code turns
to history trouble and the key switch is turned
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
 Electronic control fuel injection system (Common rail type) 1E-361
Diagnostic aid – Poor connection of terminal from connector
If the intermittent trouble is suspected, followings may – Unmatched terminals are fitted.
be the cause. – Damage of connector lock
• Improper connection of harness connector – Poor contact between terminal and wire
• Defective harness routing • Damaged harness
• Worn harness cladding – Visually check the harness for damage.
• Wire disconnection inside harness cladding – Check the relevant items on the scan tool data
Following inspections are necessary to detect these display while moving the connector and the
causes. harness which are related to the sensor. The
• Improper connection of harness connector and variation of the display indicates the faulty part.
ECM connector

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Check the DTC.
1. Turn the key switch to “OFF” for more than
10 seconds.
2 2. Start the engine. —
3. Check the DTC.
Go to “Diagnostic
Is DTC detected? Go to Step 3. aid”.
1. Turn the key switch to “OFF”.
2. Remove the coupling connector (H−94)
from the cylinder head cover case.
3. Measure the resistance between the 0.45±0.1Ω
3 coupling connector terminals (power (20°C {68°F})
supply terminal — No. 2 cylinder injector
drive signal terminal).
Is the resistance less than the specified value? Go to Step 4. Go to Step 5.
1. Check for followings in the circuit between
ECM and coupling connector (H−94) using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for
5 looseness etc. —
3. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 6.
1E-362 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check for installation condition of the coupling
connector.
1. Check for play or looseness in the
6 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 7.
1. Check for following in the circuit between
injector terminal and coupling connector.
• Open circuit
7 • High resistance —
2. If the trouble is detected, repair or replace
as required.
Is there any trouble in the circuit? Go to Step 13. Go to Step 9.
Check for installation condition of the ECM
connector.
1. Turn the key switch to “OFF”.
2. Remove the ECM.
8 3. Check for play or looseness in the —
connection.
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 10.
1. Replace the No. 2 cylinder injector.

Note:
9 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 13. —

10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 12.

 Electronic control fuel injection system (Common rail type) 1E-363

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
13 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0202 detected? Go to Step 2. Go to Step 14.
Check if other DTC is detected.
14 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM
1E-364 Electronic control fuel injection system (Common rail type)

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
4 Open circuit/ Resistance • Remove the 114 - Coupling 100Ω or 10 MΩ or
high measurement coupling connector (H−94) less more
resistance connector. terminal
• Key switch “OFF” (4H: No.7, 6H: No.7)
 Electronic control fuel injection system (Common rail type) 1E-365
DTC: P0203 (Flash code 273) Open circuit in injection nozzle #3 drive system
4HK1

2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

Injector Injector Injector Injector

(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)

3 3
3 E-35 3 E-37 E-27 E-31

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

R L/Y L/R R W L L/W W

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

Cylinder No. 3 Cylinder No. 2 Cylinder No. 1 Cylinder No. 4

Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSHK0031
1E-366 Electronic control fuel injection system (Common rail type)
6HK1

Injector Injector Injector Injector Injector Injector

(Cylinder No. 5) (Cylinder No. 6) (Cylinder No. 4) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 3)

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

3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

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

Feedback Feedback Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSWG0076

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
energizes 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-367
Cylinder No. and injection order Name
4HK1 1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6
6 7. Cylinder block
1 8. Engine front

Fuel injection is performed to each cylinder in the order

2 of 1 — 5 — 3 — 6 — 2 — 4.

5 3
Main trouble symptom
• Intense engine vibration
4
• Rough idling
• Output lowering
• Engine blow up fault

Preconditions when DTC is set

TSHK0032
• Main relay power supply voltage is 18V or more.
Name • 70 rpm or more
1. Cylinder No. 1 • DTC P0611, P1261, or P0203 is not detected.
2. Cylinder No. 2
3. Cylinder No. 3 DTC set condition
4. Cylinder No. 4
• Open/short circuit is detected in No. 3 cylinder
5. Cylinder block
injector drive circuit.
6. Engine front
• No. 3 cylinder injector monitor input signal does not
Fuel injection order is 1 — 3 — 4 — 2. exist for 2.4 seconds or more.
6HK1
Action taken when DTC is set
• Trouble is displayed on the monitor of the
machine* or diagnosis lamp comes on. (* Nothing
8
1 is displayed depending on the machine
manufacturer)
2
Back-up mode
• Injection for cylinder #3 stopped, EGR stopped
3

Recovery from failure

7
4 Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
5
failure.

The conditions to clear the MIL/DTC

6
• The present trouble turns to history trouble when
the condition is out of the range from DTC set
TSWG0157 condition (recovery from failure).
• The diagnosis lamp will go off after the code turns
to history trouble and the key switch is turned
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
1E-368 Electronic control fuel injection system (Common rail type)
Diagnostic aid – Poor connection of terminal from connector
If the intermittent trouble is suspected, followings may – Unmatched terminals are fitted.
be the cause. – Damage of connector lock
• Improper connection of harness connector – Poor contact between terminal and wire
• Defective harness routing • Damaged harness
• Worn harness cladding – Visually check the harness for damage.
• Wire disconnection inside harness cladding – Check the relevant items on the scan tool data
Following inspections are necessary to detect these display while moving the connector and the
causes. harness which are related to the sensor. The
• Improper connection of harness connector and variation of the display indicates the faulty part.
ECM connector

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Check the DTC.
1. Turn the key switch to “OFF” for more than
10 seconds.
2 2. Start the engine. —
3. Check the DTC.
Go to “Diagnostic
Is DTC detected? Go to Step 3. aid”.
1. Turn the key switch to “OFF”.
2. Remove the coupling connector (H−94)
from the cylinder head cover case.
3. Measure the resistance between the 0.45±0.1Ω
3 coupling connector terminals (power (20°C {68°F})
supply terminal — No. 3 cylinder injector
drive signal terminal).
Is the resistance less than the specified value? Go to Step 4. Go to Step 5.
1. Check for followings in the circuit between
ECM and coupling connector (H−94) using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for
5 looseness etc. —
3. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 6.
 Electronic control fuel injection system (Common rail type) 1E-369

Step Action Value YES NO

Check for installation condition of the coupling
connector.
1. Check for play or looseness in the
6 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 7.
1. Check for following in the circuit between
injector terminal and coupling connector.
• Open circuit
7 • High resistance —
2. If the trouble is detected, repair or replace
as required.
Is there any trouble in the circuit? Go to Step 13. Go to Step 9.
Check for installation condition of the ECM
connector.
1. Turn the key switch to “OFF”.
2. Remove the ECM.
8 3. Check for play or looseness in the —
connection.
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 10.
1. Replace the No. 3 cylinder injector.

Note:
9 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 13. —

10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 12.

1E-370 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
13 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0203 detected? Go to Step 2. Go to Step 14.
Check if other DTC is detected.
14 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM
 Electronic control fuel injection system (Common rail type) 1E-371

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
4 Open circuit/ Resistance • Remove the 117 - Coupling 100Ω or 10 MΩ or
high measurement coupling connector (H−94) less more
resistance connector. terminal
• Key switch “OFF” (4H: No. 6, 6H: No.
6)
1E-372 Electronic control fuel injection system (Common rail type)
DTC: P0204 (Flash code 274) Open circuit in injection nozzle #4 drive system
4HK1

2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

Injector Injector Injector Injector

(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)

3 3
3 E-35 3 E-37 E-27 E-31

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

R L/Y L/R R W L L/W W

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

Cylinder No. 3 Cylinder No. 2 Cylinder No. 1 Cylinder No. 4

Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSHK0031
 Electronic control fuel injection system (Common rail type) 1E-373
6HK1

Injector Injector Injector Injector Injector Injector

(Cylinder No. 5) (Cylinder No. 6) (Cylinder No. 4) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 3)

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

3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

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

Feedback Feedback Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSWG0076

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
energizes 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-374 Electronic control fuel injection system (Common rail type)
Cylinder No. and injection order Name
4HK1 1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder No. 5
6. Cylinder No. 6
6 7. Cylinder block
1 8. Engine front

Fuel injection is performed to each cylinder in the order

2 of 1 — 5 — 3 — 6 — 2 — 4.

5 3
Main trouble symptom
• Intense engine vibration
4
• Rough idling
• Output lowering
• Engine blow up fault

Preconditions when DTC is set

TSHK0032
• Main relay power supply voltage is 18V or more.
Name • 70 rpm or more
1. Cylinder No. 1 • DTC P0612, P1262, or P0204 is not detected.
2. Cylinder No. 2
3. Cylinder No. 3 DTC set condition
4. Cylinder No. 4
• Open/short circuit is detected in No. 4 cylinder
5. Cylinder block
injector drive circuit.
6. Engine front
• No. 4 cylinder injector monitor input signal does not
Fuel injection order is 1 — 3 — 4 — 2. exist for 2.4 seconds or more.
6HK1
Action taken when DTC is set
• Trouble is displayed on the monitor of the
machine* or diagnosis lamp comes on. (* Nothing
8
1 is displayed depending on the machine
manufacturer)
2
Back-up mode
• Injection for cylinder #4 stopped, EGR stopped
3

Recovery from failure

7
4 Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
5
failure.

The conditions to clear the MIL/DTC

6
• The present trouble turns to history trouble when
the condition is out of the range from DTC set
TSWG0157 condition (recovery from failure).
• The diagnosis lamp will go off after the code turns
to history trouble and the key switch is turned
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
 Electronic control fuel injection system (Common rail type) 1E-375
Diagnostic aid – Poor connection of terminal from connector
If the intermittent trouble is suspected, followings may – Unmatched terminals are fitted.
be the cause. – Damage of connector lock
• Improper connection of harness connector – Poor contact between terminal and wire
• Defective harness routing • Damaged harness
• Worn harness cladding – Visually check the harness for damage.
• Wire disconnection inside harness cladding – Check the relevant items on the scan tool data
Following inspections are necessary to detect these display while moving the connector and the
causes. harness which are related to the sensor. The
• Improper connection of harness connector and variation of the display indicates the faulty part.
ECM connector

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Check the DTC.
1. Turn the key switch to “OFF” for more than
10 seconds.
2 2. Start the engine. —
3. Check the DTC.
Go to “Diagnostic
Is DTC detected? Go to Step 3. aid”.
1. Turn the key switch to “OFF”.
2. Remove the coupling connector (4H: H−
94, 6H: H−95) from the cylinder head
cover case.
3. Measure the resistance between the 0.45±0.1Ω
3
coupling connector terminals (power (20°C {68°F})
supply terminal — No. 4 cylinder injector
drive signal terminal).
Is the resistance less than the specified value? Go to Step 4. Go to Step 5.
1. Check for followings in the circuit between
ECM and coupling connector (4H: H−94,
6H: H−94) using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for
5 looseness etc. —
3. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 6.
1E-376 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check for installation condition of the coupling
connector.
1. Check for play or looseness in the
6 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 7.
1. Check for following in the circuit between
injector terminal and coupling connector.
• Open circuit
7 • High resistance —
2. If the trouble is detected, repair or replace
as required.
Is there any trouble in the circuit? Go to Step 13. Go to Step 9.
Check for installation condition of the ECM
connector.
1. Turn the key switch to “OFF”.
2. Remove the ECM.
8 3. Check for play or looseness in the —
connection.
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 10.
1. Replace the No. 4 cylinder injector.

Note:
9 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 13. —

10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 12.

 Electronic control fuel injection system (Common rail type) 1E-377

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
13 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0204 detected? Go to Step 2. Go to Step 14.
Check if other DTC is detected.
14 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM
1E-378 Electronic control fuel injection system (Common rail type)

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
4 Open circuit/ Resistance • Remove the 115 - Coupling 100Ω or 10 MΩ or
high measurement coupling connector terminal less more
resistance connector. (4H: H−94 No. 8,
• Key switch “OFF” 6H: H−95 No. 2)
 Electronic control fuel injection system (Common rail type) 1E-379
DTC: P0205 (Flash code 275) Open circuit in injection nozzle #5 drive system

Injector Injector Injector Injector Injector Injector

(Cylinder No. 5) (Cylinder No. 6) (Cylinder No. 4) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 3)

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

3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

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

Feedback Feedback Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSWG0076

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
energizes 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-380 Electronic control fuel injection system (Common rail type)
Cylinder No. and injection order Back-up mode
• Injection for cylinder #5 stopped, EGR stopped

8 Recovery from failure

1
Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
2 failure.

3
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
4
7 condition (recovery from failure).
• The diagnosis lamp will go off after the code turns
5 to history trouble and the key switch is turned
“OFF” then “ON” again.
6 • Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.

TSWG0157 Diagnostic aid

Name If the intermittent trouble is suspected, followings may
1. Cylinder No. 1 be the cause.
2. Cylinder No. 2 • Improper connection of harness connector
3. Cylinder No. 3 • Defective harness routing
4. Cylinder No. 4
• Worn harness cladding
5. Cylinder No. 5
6. Cylinder No. 6 • Wire disconnection inside harness cladding
7. Cylinder block Following inspections are necessary to detect these
8. Engine front causes.
• Improper connection of harness connector and
Fuel injection is performed to each cylinder in the order ECM connector
of 1 — 5 — 3 — 6 — 2 — 4. – Poor connection of terminal from connector
– Unmatched terminals are fitted.
Main trouble symptom
– Damage of connector lock
• Intense engine vibration
– Poor contact between terminal and wire
• Rough idling
• Damaged harness
• Output lowering
– Visually check the harness for damage.
• Engine blow up fault
– Check the relevant items on the scan tool data
display while moving the connector and the
Preconditions when DTC is set
harness which are related to the sensor. The
• Main relay power supply voltage is 18V or more. variation of the display indicates the faulty part.
• 70 rpm or more
• DTC P0612, P1262, or P0205 is not detected.

DTC set condition

• Open/short circuit is detected in No. 5 cylinder
injector drive circuit.
• No. 5 cylinder injector monitor input signal does not
exist for 2.4 seconds or more.

Action taken when DTC is set

• Trouble is displayed on the monitor of the
machine* or diagnosis lamp comes on. (* Nothing
is displayed depending on the machine
manufacturer)
 Electronic control fuel injection system (Common rail type) 1E-381

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed? Go to Step 2. Go to Step 2.
Check the DTC.
1. Turn the key switch to “OFF” for more than
10 seconds.
2 2. Start the engine. —
3. Check the DTC.
Go to “Diagnostic
Is DTC detected? Go to Step 3. aid”.
1. Turn the key switch to “OFF”.
2. Remove the coupling connector (H−95)
from the cylinder head cover case.
3. Measure the resistance between the 0.45±0.1Ω
3 coupling connector terminals (power (20°C {68°F})
supply terminal — No. 5 cylinder injector
drive signal terminal).
Is the resistance less than the specified value? Go to Step 4. Go to Step 5.
1. Check for followings in the circuit between
ECM and coupling connector (H−95) using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for
5 looseness etc. —
3. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 6.
Check for installation condition of the coupling
connector.
1. Check for play or looseness in the
6 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 7.
1E-382 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for following in the circuit between
injector terminal and coupling connector.
• Open circuit
7 • High resistance —
2. If the trouble is detected, repair or replace
as required.
Is there any trouble in the circuit? Go to Step 13. Go to Step 9.
Check for installation condition of the ECM
connector.
1. Turn the key switch to “OFF”.
2. Remove the ECM.
8 3. Check for play or looseness in the —
connection.
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 10.
1. Replace the No. 5 cylinder injector.

Note:
9 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 13. —

10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 12.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

 Electronic control fuel injection system (Common rail type) 1E-383

Step Action Value YES NO

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
13 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0205 detected? Go to Step 2. Go to Step 14.
Check if other DTC is detected.
14 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
4 Open circuit/ Resistance • Remove the 120 - Coupling 100Ω or 10 MΩ or
high measurement coupling connector (H−95) less more
resistance connector. No. 7 terminal
• Key switch “OFF”
1E-384 Electronic control fuel injection system (Common rail type)
DTC: P0206 (Flash code 276) Open circuit in injection nozzle #6 drive system

Injector Injector Injector Injector Injector Injector

(Cylinder No. 5) (Cylinder No. 6) (Cylinder No. 4) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 3)

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

3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

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

Feedback Feedback Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSWG0076

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
energizes 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-385
Cylinder No. and injection order Back-up mode
• Injection for cylinder #6 stopped, EGR stopped

8 Recovery from failure

1
Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
2 failure.

3
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
4
7 condition (recovery from failure).
• The diagnosis lamp will go off after the code turns
5 to history trouble and the key switch is turned
“OFF” then “ON” again.
6 • Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.

TSWG0157 Diagnostic aid

Name If the intermittent trouble is suspected, followings may
1. Cylinder No. 1 be the cause.
2. Cylinder No. 2 • Improper connection of harness connector
3. Cylinder No. 3 • Defective harness routing
4. Cylinder No. 4
• Worn harness cladding
5. Cylinder No. 5
6. Cylinder No. 6 • Wire disconnection inside harness cladding
7. Cylinder block Following inspections are necessary to detect these
8. Engine front causes.
• Improper connection of harness connector and
Fuel injection is performed to each cylinder in the order ECM connector
of 1 — 5 — 3 — 6 — 2 — 4. – Poor connection of terminal from connector
– Unmatched terminals are fitted.
Main trouble symptom
– Damage of connector lock
• Intense engine vibration
– Poor contact between terminal and wire
• Rough idling
• Damaged harness
• Output lowering
– Visually check the harness for damage.
• Engine blow up fault
– Check the relevant items on the scan tool data
display while moving the connector and the
Preconditions when DTC is set
harness which are related to the sensor. The
• Main relay power supply voltage is 18V or more. variation of the display indicates the faulty part.
• 70 rpm or more
• DTC P0612, P1262, or P0206 is not detected.

DTC set condition

• Open/short circuit is detected in No. 6 cylinder
injector drive circuit.
• No. 6 cylinder injector monitor input signal does not
exist for 2.4 seconds or more.

Action taken when DTC is set

• Trouble is displayed on the monitor of the
machine* or diagnosis lamp comes on. (* Nothing
is displayed depending on the machine
manufacturer)
1E-386 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed? Go to Step 2. Go to Step 2.
Check the DTC.
1. Turn the key switch to “OFF” for more than
10 seconds.
2 2. Start the engine. —
3. Check the DTC.
Go to “Diagnostic
Is DTC detected? Go to Step 3. aid”.
1. Turn the key switch to “OFF”.
2. Remove the coupling connector (H−95)
from the cylinder head cover case.
3. Measure the resistance between the 0.45±0.1Ω
3 coupling connector terminals (power (20°C {68°F})
supply terminal — No. 6 cylinder injector
drive signal terminal).
Is the resistance less than the specified value? Go to Step 4. Go to Step 5.
1. Check for followings in the circuit between
ECM and coupling connector (H−95) using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for
5 looseness etc. —
3. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 6.
Check for installation condition of the coupling
connector.
1. Check for play or looseness in the
6 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 7.
 Electronic control fuel injection system (Common rail type) 1E-387

Step Action Value YES NO

1. Check for following in the circuit between
injector terminal and coupling connector.
• Open circuit
7 • High resistance —
2. If the trouble is detected, repair or replace
as required.
Is there any trouble in the circuit? Go to Step 13. Go to Step 9.
Check for installation condition of the ECM
connector.
1. Turn the key switch to “OFF”.
2. Remove the ECM.
8 3. Check for play or looseness in the —
connection.
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 10.
1. Replace the No. 6 cylinder injector.

Note:
9 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 13. —

10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 12.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

1E-388 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
13 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0206 detected? Go to Step 2. Go to Step 14.
Check if other DTC is detected.
14 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
4 Open circuit/ Resistance • Remove the 118 - Coupling 100Ω or 10 MΩ or
high measurement coupling connector (H−95) less more
resistance connector. No. 6 terminal
• Key switch “OFF”
 Electronic control fuel injection system (Common rail type) 1E-389
DTC: P0219 (Flash code 543) Overrun

Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V

CKP CKP
HIGH LOW
signal signal

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 2 H-20 1 H-20

0.75 Br

0.75 0.75 0.75

0.75 0.75
W/R B/W Br
B/R W/L

2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W

CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113

CMP sensor Common rail pressure sensor

TSHK0033

Description of circuit Action taken when DTC is set

The engine control module (ECM) detects the engine • Trouble is displayed on the monitor of the
speed based on the crankshaft position (CKP) sensor machine* or diagnosis lamp comes on. (* Nothing
signal. The ECM stops the fuel injection to lower the is displayed depending on the machine
engine speed when the engine speed exceeds the manufacturer)
specified value.
Back-up mode
Main trouble symptom • Limited injection amount 1
Output lowering • Limitation is lifted if the speed decreases

Preconditions when DTC is set Recovery from failure

• Key switch input voltage is 18V or more. Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
DTC set condition failure.
• The engine speed exceeds setting value* for 1
second or more (* depending on the machine
manufacturer)
1E-390 Electronic control fuel injection system (Common rail type)
The conditions to clear the MIL/DTC Diagnostic aid
• The present trouble turns to history trouble when • Load (fluid pressure pump etc.) is light.
the condition is out of the range from DTC set • Crankshaft position (CKP) sensor, camshaft
condition (recovery from failure). position (CMP) sensor fault (signal fault etc.)
• The diagnosis lamp will go off after the code turns • Engine body fault (supply pump, injector, body,
to history trouble and the key switch is turned etc.)
“OFF” then “ON” again. • ECM internal trouble
• Using the scan tool, or memory clear switch and • Check the connector for poor contact, the harness
diagnostic switch operation enables to clear DTCs. for fault such as wear or bend, and the wire inside
the harness for loosened wire causing short circuit
to other circuits. Also, perform the function
diagnosis to check the operation and control of
each part. Repair if faulty.
• When this DTC is detected, check the engine body
for trouble such as seizure and breakage.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Confirm the driving status (improper operation
of the vehicle due to engine over speed).
2 (Interview the operator for driving status in the —
past.)
Has the vehicle been operated improperly? Go to Step 3. Go to Step 4.
Tell the operator that it is the over speed
caused by improper operation, and give a
3 driving instruction. —

Is the procedure completed? Go to Step 4. —

Check for adverse effect (fault in the engine
body) caused by the engine over speed.
4 Repair or replace if fault is found. —

Is the procedure completed? Go to Step 5. —

Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
5 2. Turn the key switch to “OFF” for more than —
10 seconds.
3. Test run with the “Preconditions when
DTC is set”.
4. Check the DTC.
Go to each DTC
Is DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-391
DTC: P0237 (Flash code 32) Boost sensor pressure fault (low voltage fault, open circuit)

Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal

74 E-56 109 E-56 91 E-56 95 E-56

15 H-20 17 H-20 16 H-20 8 H-20

0.75 0.75 0.75 0.75 0.75

B/R R/L R/L L R/W

2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

Boost temperature sensor

Boost pressure sensor

TSWG0079

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

The boost pressure sensor is installed to the intake through 5-V power supply circuit, and grounds to the
manifold. The boost pressure sensor outputs the inside of the ECM through ground circuit. Also, the
voltage corresponding to the internal pressure of the boost pressure sensor outputs the signal voltage to the
intake manifold, and the ECM detects the boost by this ECM through boost pressure sensor signal circuit. The
signal. The boost pressure sensor includes following ECM detects a low boost condition (the engine load is
circuits. low) when the signal voltage from the boost pressure
sensor is low, and a high boost condition (the engine
• 5-V power supply circuit
load is high) when the signal voltage from the boost
• Ground circuit pressure sensor is high.
• Boost pressure sensor signal circuit The ECM sets the DTC when the signal voltage from
the boost pressure sensor is less than the normal
range.
1E-392 Electronic control fuel injection system (Common rail type)
Main trouble symptom • Using the scan tool, or memory clear switch and
Operationality is affected. diagnostic switch operation enables to clear DTCs.

Preconditions when DTC is set Diagnostic aid

• Key switch input voltage is 18V or more. If the intermittent trouble is suspected, followings may
be the cause.
• DTC P1630 or P1634 is not detected.
• Improper connection of harness connector
DTC set condition • Defective harness routing
• Boost pressure sensor voltage is 0.1V or less for 3 • Worn harness cladding
seconds or more. • Wire disconnection inside harness cladding
Following inspections are necessary to detect these
Action taken when DTC is set causes.
• Trouble is displayed on the monitor of the • Improper connection of harness connector and
machine* or diagnosis lamp comes on. (* Nothing ECM connector
is displayed depending on the machine – Poor connection of terminal from connector
manufacturer) – Unmatched terminals are fitted.
– Damage of connector lock
Back-up mode – Poor contact between terminal and wire
• Specified back-up value (depending on the • Damaged harness
machine manufacturer) (4HK1) – Visually check the harness for damage.
• Boost pressure default setting (150 MPa {21756 – Check the relevant items on the scan tool data
psi}) (6HK1) display while moving the connector and the
• Boost pressure correction/EGR stopped (6HK1) harness which are related to the sensor. The
variation of the display indicates the faulty part.
Recovery from failure
Refer to “List of diagnostic trouble code” and “About Test description
recovery from failure” in this section for recovery from Numbers below indicate step numbers in the chart.
failure. 3.. In case of present trouble, the “MAP (manifold
absolute pressure) sensor” displays less than the
The conditions to clear the MIL/DTC threshold value. If more than the threshold value,
• The present trouble turns to history trouble when identify the cause by referring to “Diagnostic aid”.
the condition is out of the range from DTC set 5. If “MAP (manifold absolute pressure) sensor”
condition (recovery from failure). displays more than the specified value when terminals
• The diagnosis lamp will go off after the code turns between the boost pressure sensor connector are
to history trouble and the key switch is turned shorted, the circuit beyond the sensor is normal
“OFF” then “ON” again. including ECM.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 14.
1. Turn the key switch to “ON”.
2. Check for “MAP (manifold absolute
pressure) sensor” on the data display
3 using scan tool. 0.1V

Is the “MAP (manifold absolute pressure) Go to “Diagnostic

sensor” less than the threshold value? Go to Step 4. aid”.
 Electronic control fuel injection system (Common rail type) 1E-393

Step Action Value YES NO

Check for installation condition of the boost
pressure sensor connector, ECM connector
and coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 5.
1. Turn the key switch to “OFF”.
2. Disconnect the boost pressure sensor
connector.
3. Short between the boost pressure sensor
connector power supply terminal and the
signal terminal using jump cable.
5 4. Turn the key switch to “ON”. 4.8V
5. Check for “MAP (manifold absolute
pressure) sensor” on the data display
using scan tool.
Is the “MAP (manifold absolute pressure)
sensor” more than the specified value? Go to Step 8. Go to Step 9.
1. Check for followings in the power supply
circuit between ECM and boost pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and boost pressure sensor
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 —
• Short circuit to boost pressure sensor
ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
1E-394 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the boost pressure sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

10 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. Go to Step 11.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
12 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0237 detected? Go to Step 2. Go to Step 13.
Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine.
2. Check the display of boost pressure 508MPa
sensor. (73679 psi)
14
(Displayed
Does the display of “Boost pressure sensor” error value) Go to “Diagnostic
show error value? Go to Step 15. aid”.
 Electronic control fuel injection system (Common rail type) 1E-395

Step Action Value YES NO

Check for installation condition of the boost
pressure sensor connector, ECM connector
and coupling connector.
1. Check for play or looseness in the
15 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 13. Go to Step 16.
1. Check for followings in the power supply
circuit between ECM and boost pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
16 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and boost pressure sensor
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
17 —
• Short circuit to boost pressure sensor
ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 8.
1E-396 Electronic control fuel injection system (Common rail type)
About boost pressure sensor 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.

3 2 1

TSWG0062

Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply Name
1. Breaker box
Characteristics of boost pressure sensor 2. DMM

The output voltage of boost pressure sensor changes

according to the boost pressure. The scan tool with CAN
communication displays a fixed value when the value
exceeds the threshold voltage. Therefore, judge as it is
more than the threshold value if the value of 40 MPa
(5802 psi) or 350 MPa (50763 psi) is not changed.
When error occurs, error value (508 MPa {73679 psi}) is
displayed.
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
display both voltage and physical value.

(V)
4.75026

0.100082

40(5802) 350(50763)
MPa(psi)
TSWG0063
 Electronic control fuel injection system (Common rail type) 1E-397

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Open circuit/ Resistance • Disconnect the 95 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector power less more
resistance connector. supply terminal
• Key switch “OFF”
7 Short circuit to Resistance • Disconnect the 91 - 109 10 MΩ or 100Ω or
ground circuit/ measurement sensor 91 - Ground more less
ground connector.
• Key switch “OFF”
Open circuit/ Resistance • Disconnect the 91 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector signal less more
resistance connector. terminal
• Key switch “OFF”

On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
1E-398 Electronic control fuel injection system (Common rail type)
DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault, short to power
supply circuit, ground open circuit)

Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal

74 E-56 109 E-56 91 E-56 95 E-56

15 H-20 17 H-20 16 H-20 8 H-20

0.75 0.75 0.75 0.75 0.75

B/R R/L R/L L R/W

2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

Boost temperature sensor

Boost pressure sensor

TSWG0079

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

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

Main trouble symptom

Black smoke emitted
 Electronic control fuel injection system (Common rail type) 1E-399
Preconditions when DTC is set Diagnostic aid
• Key switch input voltage is 18V or more. If the intermittent trouble is suspected, followings may
• DTC P1630 or P1634 is not detected. be the cause.
• Improper connection of harness connector
DTC set condition • Defective harness routing
• Boost pressure sensor voltage is 4.9V or more for • Worn harness cladding
3 seconds or more. • Wire disconnection inside harness cladding
Following inspections are necessary to detect these
Action taken when DTC is set causes.
• Trouble is displayed on the monitor of the • Improper connection of harness connector and
machine* or diagnosis lamp comes on. (* Nothing ECM connector
is displayed depending on the machine – Poor connection of terminal from connector
manufacturer) – Unmatched terminals are fitted.
– Damage of connector lock
Back-up mode
– Poor contact between terminal and wire
• Specified back-up value (depending on the
• Damaged harness
machine manufacturer) (4HK1)
– Visually check the harness for damage.
• Boost pressure default setting (150 MPa {21756
psi}) (6HK1) – Check the relevant items on the scan tool data
display while moving the connector and the
• Boost pressure correction/EGR stopped (6HK1)
harness which are related to the sensor. The
variation of the display indicates the faulty part.
Recovery from failure
Refer to “List of diagnostic trouble code” and “About Test description
recovery from failure” in this section for recovery from
Numbers below indicate step numbers in the chart.
failure.
3. In the case of present trouble, the “MAP (manifold
absolute pressure) sensor” displays more than the
The conditions to clear the MIL/DTC
specified value. If less than the specified value, identify
• The present trouble turns to history trouble when the cause by referring to “Diagnostic aid”.
the condition is out of the range from DTC set 5. If “MAP (manifold absolute pressure) sensor”
condition (recovery from failure). displays less than the specified value when the boost
• The diagnosis lamp turns off when the trouble code pressure sensor connector is removed, the circuit
turns to the history trouble. beyond the sensor is normal including ECM.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear history
trouble.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 14.
1. Turn the key switch to “ON”.
2. Check for “MAP (manifold absolute
pressure) sensor” on the data display
3 using scan tool. 4.9V

Is the “MAP (manifold absolute pressure) Go to “Diagnostic

sensor” more than the specified value? Go to Step 4. aid”.
1E-400 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check for installation condition of the boost
pressure sensor connector, ECM connector
and coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 5.
1. Turn the key switch to “OFF”.
2. Disconnect the boost pressure sensor
connector.
3. Turn the key switch to “ON”.
5 4. Check for “MAP (manifold absolute 0.1V
pressure) sensor” on the data display
using scan tool.
Is the “MAP (manifold absolute pressure)
sensor” less than the specified value? Go to Step 8. Go to Step 6.
1. Check the signal circuit between ECM and
boost pressure sensor for short circuit to
the power supply circuit or ignition power
supply circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —
Important:
If the boost pressure sensor circuit is shorted
to the power supply circuit, the sensor may be
broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the ground circuit
between ECM and boost pressure sensor
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the boost pressure sensor.
8 —
Is the procedure completed? Go to Step 12. —
 Electronic control fuel injection system (Common rail type) 1E-401

Step Action Value YES NO

9 Is EMPS available? — Go to Step 10. Go to Step 11.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. Go to Step 11.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
12 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0238 detected? Go to Step 2. Go to Step 13.
Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine.
2. Check the display of boost pressure 508 MPa
sensor. (73679 psi)
14
(Displayed
Does the display of “Boost pressure sensor” error value) Go to “Diagnostic
show error value? Go to Step 15. aid”.
Check for installation condition of the boost
pressure sensor connector, ECM connector
and coupling connector.
1. Check for play or looseness in the
15 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 16.
1E-402 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the signal circuit between ECM and
boost pressure sensor for short circuit to
the power supply circuit or ignition power
supply circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
16 board check procedure for sensors”. —
Important:
If the boost pressure sensor circuit is shorted
to the power supply circuit, the sensor may be
broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 12. Go to Step 17.
1. Check for followings in the ground circuit
between ECM and boost pressure sensor
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
17 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 8.
 Electronic control fuel injection system (Common rail type) 1E-403
About boost pressure sensor 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.

3 2 1

TSWG0062

Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply Name
1. Breaker box
Characteristics of boost pressure sensor 2. DMM

The output voltage of boost pressure sensor changes

according to the boost pressure. The scan tool with CAN
communication displays a fixed value when the value
exceeds the threshold voltage. Therefore, judge as it is
more than the threshold value if the value of 40 MPa
(5802 psi) or 350 MPa (50763 psi) is not changed.
When error occurs, error value (508 MPa {73679 psi}) is
displayed.
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
display both voltage and physical value.

(V)
4.75026

0.100082

40(5802) 350(50763)
MPa(psi)
TSWG0063
1E-404 Electronic control fuel injection system (Common rail type)

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Voltage • Disconnect the 91 - Ground 0V 18V or
power supply measurement sensor more
circuit connector.
• Key switch “ON”
7 Open circuit/ Resistance • Disconnect the 109 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector ground less more
resistance connector. terminal
• Key switch “OFF”

On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
 Electronic control fuel injection system (Common rail type) 1E-405
DTC: P0335 (Flash code 15) Crank sensor fault (no signal)

Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V

CKP CKP
HIGH LOW
signal signal

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 2 H-20 1 H-20

0.75 Br

0.75 0.75 0.75

0.75 0.75
W/R B/W Br
B/R W/L

2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W

CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113

CMP sensor Common rail pressure sensor

TSHK0033

Description of circuit • DTC P0335, P0336, P0340, P0341, or P1345 is

The crankshaft position (CKP) sensor detects the not detected.
engine speed. When the sensing hole installed in the • Engine under operation
flywheel passes the tip of the CKP sensor, a voltage is
generated and turned into a pulse signal. The engine DTC set condition
control module (ECM) reads this pulse signal, and • Cam signal exists but no crank signal.
obtains the engine speed and injection timing based on
the signal. Action taken when DTC is set
• Trouble is displayed on the monitor of the
Main trouble symptom
machine* or diagnosis lamp comes on. (* Nothing
• Output lowering is displayed depending on the machine
• White smoke emitted manufacturer)
• Intense engine vibration possible
• Engine stall possible (restart is possible when Back-up mode
camshaft position sensor is normal.) • Control based on cam when cam sensor is normal

Preconditions when DTC is set

• Cam pulse is normal.
1E-406 Electronic control fuel injection system (Common rail type)
Recovery from failure – Poor connection of terminal from connector
Refer to “List of diagnostic trouble code” and “About – Unmatched terminals are fitted.
recovery from failure” in this section for recovery from – Damage of connector lock
failure. – Poor contact between terminal and wire
• Damaged harness
The conditions to clear the MIL/DTC
– Visually check the harness for damage.
• The present trouble turns to history trouble when – Check the relevant items on the scan tool data
the condition is out of the range from DTC set display while moving the connector and the
condition (recovery from failure). harness which are related to the sensor. The
• The diagnosis lamp will go off after the code turns variation of the display indicates the faulty part.
to history trouble and the key switch is turned • For crank sensor fault, DTC won’t be detected
“OFF” then “ON” again. unless the engine cranks for 14 revolutions.
• Using the scan tool, or memory clear switch and Especially when running with low speed such as
diagnostic switch operation enables to clear DTCs. idling, engine stalls before cranking for 14
revolutions if no crank signal exist. In this case, the
Diagnostic aid back-up mode will not be active because DTC is
If the intermittent trouble is suspected, followings may not detected. Therefore, the engine can be
be the cause. restarted even after it stalls, making it difficult to
• Improper connection of harness connector identify the fault. If the engine experienced stall,
raise the engine speed up to No Load Max, and
• Defective harness routing
check if crank sensor fault is detected while
• Worn harness cladding cranking for 14 revolutions. If crank sensor fault is
• Wire disconnection inside harness cladding detected at No Load Max, DTC will be detected. If
Following inspections are necessary to detect these intermittent trouble is found, raise the engine
causes. speed up to No Load Max, and check if DTC
• Improper connection of harness connector and P0355 is detected.
ECM connector

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check for installation condition of the
crankshaft position (CKP) sensor.
1. Turn the key switch to “OFF”.
2. Visually check the sensor for installation
2 condition such as play or looseness. —
3. If the trouble is detected, repair as
required.
Is the procedure completed? Go to Step 3. —
Check for installation condition of the CKP
sensor, ECM and coupling connector.
1. Check for play or looseness in the
3 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the procedure completed? Go to Step 4. —
 Electronic control fuel injection system (Common rail type) 1E-407

Step Action Value YES NO

Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
4 2. Turn the key switch to “OFF” for more than —
10 seconds.
3. Start the engine, and test run with the
“Preconditions when DTC is set”.
4. Check the DTC.
Is DTC detected? Go to Step 5. Go to Step 12.
Check the CKP sensor body. Between
1. Turn the key switch to “OFF”. terminals:
2. Remove the harness from the CKP 108.5 —
sensor. 142.5Ω; Each
5
terminal —
3. Measure the resistance between the
ground: ∞Ω (at
sensor connector terminals.
normal
Is the resistance within the specified value? temperature) Go to Step 6. Go to Step 7.
1. Check for followings in the circuit between
ECM and CKP sensor using breaker box
or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

6 • Open circuit —
• High resistance
• Short circuit to ground
• Short circuit between terminals
• Short circuit to power supply circuit or
ignition power supply circuit
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 8.
Replace the CKP sensor.
7 —
Is the procedure completed? Go to Step 11. —
8 Is EMPS available? — Go to Step 9. Go to Step 10.
1E-408 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

9 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. Go to Step 10.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
11 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0335 detected? Go to Step 2. Go to Step 12.
Check if other DTC is detected.
12 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-409
About CKP sensor 6HK1

TSWG0064 TSHK0129

Name About CKP sensor and CMP sensor signals

1. GND
2. Power supply 4HK1

4HK1

TSHK0042

TSHK0128
1E-410 Electronic control fuel injection system (Common rail type)
6HK1 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. CMP signal
Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Open circuit/ Resistance • Disconnect the 106 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector (−) less more
resistance connector. terminal
• Key switch “OFF” 107 - Sensor
connector (+)
terminal
Short circuit to Resistance • Disconnect the 106 - Ground 10 MΩ or 100Ω or
ground measurement sensor 107 - Ground more less
connector.
• Key switch “OFF”
Short circuit Resistance • Disconnect the 106 - 107 10 MΩ or 100Ω or
between measurement sensor more less
terminals connector.
• Key switch “OFF”
Short circuit to Voltage • Disconnect the 106 - Ground 0V 18V or
power supply measurement sensor 107 - Ground more
circuit connector.
• Key switch “ON”
 Electronic control fuel injection system (Common rail type) 1E-411
On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
1E-412 Electronic control fuel injection system (Common rail type)
DTC: P0336 (Flash code 15) Crank sensor fault (signal fault)

Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V

CKP CKP
HIGH LOW
signal signal

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 2 H-20 1 H-20

0.75 Br

0.75 0.75 0.75

0.75 0.75
W/R B/W Br
B/R W/L

2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W

CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113

CMP sensor Common rail pressure sensor

TSHK0033

Description of circuit • DTC P0335, P0336, P0340, P0341, or P1345 is

The crankshaft position (CKP) sensor detects the not detected.
engine speed. When the sensing hole installed in the • Engine under operation
flywheel housing passes the tip of the CKP sensor, a
voltage is generated and turned into a pulse signal. The DTC set condition
engine control module (ECM) reads this pulse signal, • Number of pulse for crank signal is mismatched.
and obtains the engine speed and injection timing
based on the signal. Action taken when DTC is set
• Trouble is displayed on the monitor of the
Main trouble symptom
machine* or diagnosis lamp comes on. (* Nothing
• Output lowering is displayed depending on the machine
• White smoke emitted manufacturer)
• Intense engine vibration possible
• Engine stall possible (restart is possible when Back-up mode
camshaft position sensor is normal.) • Control based on cam when cam sensor is normal

Preconditions when DTC is set

• Cam pulse is normal.
 Electronic control fuel injection system (Common rail type) 1E-413
Recovery from failure – Poor connection of terminal from connector
Refer to “List of diagnostic trouble code” and “About – Unmatched terminals are fitted.
recovery from failure” in this section for recovery from – Damage of connector lock
failure. – Poor contact between terminal and wire
• Damaged harness
The conditions to clear the MIL/DTC
– Visually check the harness for damage.
• The present trouble turns to history trouble when – Check the relevant items on the scan tool data
the condition is out of the range from DTC set display while moving the connector and the
condition (recovery from failure). harness which are related to the sensor. The
• The diagnosis lamp will go off after the code turns variation of the display indicates the faulty part.
to history trouble and the key switch is turned • For crank sensor fault, DTC won’t be detected
“OFF” then “ON” again. unless the engine cranks for 14 revolutions.
• Using the scan tool, or memory clear switch and Especially when running with low speed such as
diagnostic switch operation enables to clear DTCs. idling, engine stalls before cranking for 14
revolutions if no crank signal exist. In this case, the
Diagnostic aid back-up mode will not be active because DTC is
If the intermittent trouble is suspected, followings may not detected. Therefore, the engine can be
be the cause. restarted even after it stalls, making it difficult to
• Improper connection of harness connector identify the fault. If the engine experienced stall,
raise the engine speed up to No Load Max, and
• Defective harness routing
check if crank sensor fault is detected while
• Worn harness cladding cranking for 14 revolutions. If crank sensor fault is
• Wire disconnection inside harness cladding detected at No Load Max, DTC will be detected. If
Following inspections are necessary to detect these intermittent trouble is found, raise the engine
causes. speed up to No Load Max, and check if DTC
• Improper connection of harness connector and P0355 is detected.
ECM connector

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check for installation condition of the
crankshaft position (CKP) sensor.
1. Turn the key switch to “OFF”.
2. Visually check the sensor for installation
2 condition such as play or looseness. —
3. If the trouble is detected, repair as
required.
Is the procedure completed? Go to Step 3. —
Check for installation condition of the CKP
sensor, ECM and coupling connector.
1. Check for play or looseness in the
3 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the procedure completed? Go to Step 4. —
1E-414 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
4 2. Turn the key switch to “OFF” for more than —
10 seconds.
3. Start the engine, and test run with the
“Preconditions when DTC is set”.
4. Check the DTC.
Is DTC detected? Go to Step 5. Go to Step 12.
1. Check the CKP sensor circuit for short
circuit to other signal circuit using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.

5 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair or replace

as required.
Is the trouble detected? Go to Step 12. Go to Step 6.
Check the CKP sensor body.
1. Turn the key switch to “OFF”. Between
2. Remove the harness from the CKP terminals:
sensor. 108.5 —
3. Measure the resistance between the 142.5Ω; Each
6
sensor connector terminals. terminal —
ground: ∞Ω (at
4. Remove the CKP sensor, and check the
normal
sensor tip for scratch or damage.
temperature)
Is the CKP sensor normal? Go to Step 8. Go to Step 7.
Replace the CKP sensor.
7 —
Is the procedure completed? Go to Step 12. —
1. Visually check the flywheel for chipped
tooth.
8 2. If the trouble is detected, replace it. —

Is the trouble detected? Go to Step 12. Go to Step 9.

9 Is EMPS available? — Go to Step 10. Go to Step 11.
 Electronic control fuel injection system (Common rail type) 1E-415

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

10 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. Go to Step 11.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
12 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0336 detected? Go to Step 2. Go to Step 13.
Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1E-416 Electronic control fuel injection system (Common rail type)
About CKP sensor 6HK1

TSWG0064 TSHK0129

Name About CKP sensor and CMP sensor signals

1. GND
2. Power supply 4HK1

4HK1

TSHK0042

TSHK0128
 Electronic control fuel injection system (Common rail type) 1E-417
6HK1 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. CMP signal
Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
5 Short circuit to Voltage • Disconnect the 106 - Ground 0V 1V or
other signal measurement sensor 107 - Ground more
circuit connector.
• Key switch “ON”

On-board check procedure for sensors Name

1. Coupling connector between engine — the
3 machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
2 1
harness. Check from step 1 again.
4 • If only step 1 is faulty, replace the sensor.

TSWG0197
1E-418 Electronic control fuel injection system (Common rail type)
DTC: P0340 (Flash code 14) Cam sensor fault (no signal)

Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V

CKP CKP
HIGH LOW
signal signal

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 2 H-20 1 H-20

0.75 Br

0.75 0.75 0.75

0.75 0.75
W/R B/W Br
B/R W/L

2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W

CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113

CMP sensor Common rail pressure sensor

TSHK0033

Description of circuit DTC set condition

The camshaft position (CMP) sensor detects the • Crank signal exists but no cam signal.
camshaft rotation and identifies the cylinder. When the
pulsar installed in the camshaft passes the tip of the Action taken when DTC is set
camshaft position (CMP) sensor, a voltage is generated • Trouble is displayed on the monitor of the
and turned into a pulse signal. The engine control machine* or diagnosis lamp comes on. (* Nothing
module (ECM) reads this pulse signal, and identifies is displayed depending on the machine
the cylinder based on the signal. manufacturer)

Main trouble symptom Back-up mode

• Engine does not start (restart). • Engine running based on crank when it is normal
• Behavior does not change during engine running. • After engine stops: Unable to identify cylinder
(unable to restart)
Preconditions when DTC is set
• Crank pulse is normal. Recovery from failure
• DTC P0335, P0336, P0340, P0341, P1345, or Refer to “List of diagnostic trouble code” and “About
P1635 is not detected. recovery from failure” in this section for recovery from
• Engine under operation failure.
 Electronic control fuel injection system (Common rail type) 1E-419
The conditions to clear the MIL/DTC • Wire disconnection inside harness cladding
• The present trouble turns to history trouble when Following inspections are necessary to detect these
the condition is out of the range from DTC set causes.
condition (recovery from failure). • Improper connection of harness connector and
• The diagnosis lamp will go off after the code turns ECM connector
to history trouble and the key switch is turned – Poor connection of terminal from connector
“OFF” then “ON” again. – Unmatched terminals are fitted.
• Using the scan tool, or memory clear switch and – Damage of connector lock
diagnostic switch operation enables to clear DTCs. – Poor contact between terminal and wire
• Damaged harness
Diagnostic aid
– Visually check the harness for damage.
If the intermittent trouble is suspected, followings may – Check the relevant items on the scan tool data
be the cause. display while moving the connector and the
• Improper connection of harness connector harness which are related to the sensor. The
• Defective harness routing variation of the display indicates the faulty part.
• Worn harness cladding • The cam gears are out of installation phase by one
tooth.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check for installation condition of the CMP
sensor.
1. Turn the key switch to “OFF”.
2. Visually check the sensor for installation
2 condition such as play or looseness. —
3. If the trouble is detected, repair as
required.
Is the procedure completed? Go to Step 3. —
Check for installation condition of the CMP
sensor, ECM and coupling connector.
1. Check for play or looseness in the
3 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the procedure completed? Go to Step 4. —
Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
4 2. Turn the key switch to “OFF” for more than —
10 seconds.
3. Start the engine, and test run with the
“Preconditions when DTC is set”.
4. Check the DTC.
Is DTC detected? Go to Step 5. Go to Step 15.
Remove the CMP sensor, and check the
5 sensor tip for scratch or damage. —
Is the CMP sensor normal? Go to Step 6. Go to Step 9.
1E-420 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for followings in the power supply
circuit between ECM and CMP sensor
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —

• Open circuit
• High resistance
• Short circuit to ground
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 15. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and CMP sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 —
• Open circuit
• High resistance
• Short circuit to power supply circuit or
ignition power supply circuit
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 15. Go to Step 8.
1. Check for followings in the shield circuit
between ECM and CMP sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
8 —
• Open circuit
• High resistance
• Short circuit to power supply circuit or
ignition power supply circuit
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 15. Go to Step 10.
Replace the CMP sensor.
9 —
Is the procedure completed? Go to Step 10. —
 Electronic control fuel injection system (Common rail type) 1E-421

Step Action Value YES NO

1. Visually check the camshaft gear for fault.
2. Check the alignment mark in the timing
gear.
10 3. If the trouble is detected, repair or replace —
it.
Is the trouble detected? Go to Step 15. Go to Step 11.
Replace the supply pump.

Note:
11 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 14. —

12 Is EMPS available? — Go to Step 13. Go to Step 14.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
13 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 15. Go to Step 14.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
14 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 15. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
15 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0340 detected? Go to Step 2. Go to Step 16.
Check if other DTC is detected.
16 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1E-422 Electronic control fuel injection system (Common rail type)
About camshaft position (CMP) sensor 6HK1

15

TSWG0152

Name Name
1. Shield 1. CMP sensor
2. −
3. +
About CKP sensor and CMP sensor signals
4HK1 4HK1

15

1
1

TSHK0040
TSHK0042
 Electronic control fuel injection system (Common rail type) 1E-423
6HK1 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. CMP signal
Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Open circuit/ Resistance • Disconnect the 99 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector power less more
resistance connector. supply terminal
• Key switch “OFF”
Short circuit to Resistance • Disconnect the 99 - Ground 10 MΩ or 100Ω or
ground measurement sensor more less
connector.
• Key switch “OFF”
7 Open circuit/ Resistance • Disconnect the 98 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector signal less more
resistance connector. terminal
• Key switch “OFF”
Short circuit to Voltage • Disconnect the 98 - Ground 0V 18V or
power supply measurement sensor more
circuit connector.
• Key switch “ON”
8 Open circuit/ Resistance • Disconnect the 100 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector shield less more
resistance connector. terminal
• Key switch “OFF”
Short circuit to Voltage • Disconnect the 100 - Ground 0V 18V or
power supply measurement sensor more
circuit connector.
• Key switch “ON”
1E-424 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

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
 Electronic control fuel injection system (Common rail type) 1E-425
DTC: P0341 (Flash code 14) Cam sensor fault (signal fault)

Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V

CKP CKP
HIGH LOW
signal signal

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 2 H-20 1 H-20

0.75 Br

0.75 0.75 0.75

0.75 0.75
W/R B/W Br
B/R W/L

2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W

CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113

CMP sensor Common rail pressure sensor

TSHK0033

Description of circuit DTC set condition

The camshaft position (CMP) sensor detects the • When unnecessary cam pulse is detected, or when
camshaft rotation and identifies the cylinder. When the shortage of cam pulse is detected.
pulsar installed in the camshaft passes the tip of the
CMP sensor, a voltage is generated and turned into a Action taken when DTC is set
pulse signal. The engine control module (ECM) reads • Trouble is displayed on the monitor of the
this pulse signal, and identifies the cylinder based on machine* or diagnosis lamp comes on. (* Nothing
the signal. is displayed depending on the machine
manufacturer)
Main trouble symptom
• Engine does not start (restart). Back-up mode
• Behavior does not change during engine running. • Engine running based on crank when it is normal
• After engine stops: Unable to identify cylinder
Preconditions when DTC is set (unable to restart)
• Crank pulse is normal.
• DTC P0335, P0336, P0340, P0341, P1345, or
P1635 is not detected.
• Engine under operation
1E-426 Electronic control fuel injection system (Common rail type)
Recovery from failure • Improper connection of harness connector
Refer to “List of diagnostic trouble code” and “About • Defective harness routing
recovery from failure” in this section for recovery from • Worn harness cladding
failure. • Wire disconnection inside harness cladding
Following inspections are necessary to detect these
The conditions to clear the MIL/DTC causes.
• The present trouble turns to history trouble when • Improper connection of harness connector and
the condition is out of the range from DTC set ECM connector
condition (recovery from failure). – Poor connection of terminal from connector
• The diagnosis lamp will go off after the code turns – Unmatched terminals are fitted.
to history trouble and the key switch is turned – Damage of connector lock
“OFF” then “ON” again.
– Poor contact between terminal and wire
• Using the scan tool, or memory clear switch and
• Damaged harness
diagnostic switch operation enables to clear DTCs.
– Visually check the harness for damage.
Diagnostic aid – Check the relevant items on the scan tool data
display while moving the connector and the
If the intermittent trouble is suspected, followings may
harness which are related to the sensor. The
be the cause.
variation of the display indicates the faulty part.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check for installation condition of the CMP
sensor.
1. Turn the key switch to “OFF”.
2. Visually check the sensor for installation
2 condition such as play or looseness. —
3. If the trouble is detected, repair as
required.
Is the procedure completed? Go to Step 3. —
Check for installation condition of the CMP
sensor, ECM and coupling connector.
1. Check for play or looseness in the
3 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the procedure completed? Go to Step 4. —
Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
4 2. Turn the key switch to “OFF” for more than —
10 seconds.
3. Start the engine, and test run with the
“Preconditions when DTC is set”.
4. Check the DTC.
Is DTC detected? Go to Step 5. Go to Step 11.
Remove the CMP sensor, and check the
5 sensor tip for scratch or damage. —
Is the CMP sensor normal? Go to Step 6. Go to Step 8.
 Electronic control fuel injection system (Common rail type) 1E-427

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Remove the harness from the CMP
sensor.
3. Connect the breaker box or DMM between
the CMP sensor terminals.
Refer to “Breaker box inspection
procedure”.
6 0V
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

4. Turn the key switch to “ON”.

Is the DMM indication specified value? Go to Step 8. Go to Step 7.
1. Check the CMP sensor circuit for short
circuit to other signal circuit using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.

7 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair or replace

as required.
Is the trouble detected? Go to Step 14. Go to Step 9.
Replace the CMP sensor.
8 —
Is the procedure completed? Go to Step 14. —
1. Visually check the camshaft gear for fault.
2. Check the alignment mark in the timing
gear.
9 3. If the trouble is detected, repair or replace —
it.
Is the trouble detected? Go to Step 14. Go to Step 10.
Replace the supply pump.

Note:
10 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 11. —

11 Is EMPS available? — Go to Step 12. Go to Step 13.
1E-428 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

12 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 14. Go to Step 13.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
13 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 14. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
14 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0341 detected? Go to Step 2. Go to Step 15.
Check if other DTC is detected.
15 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-429
About CMP sensor 6HK1

15

TSWG0152

Name Name
1. Shield 1. CMP sensor
2. −
3. +
About CKP sensor and CMP sensor signals
4HK1 4HK1

15

1
1

TSHK0040
TSHK0042
1E-430 Electronic control fuel injection system (Common rail type)
6HK1 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. CMP signal
Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
7 Short circuit to Voltage • Disconnect the 98 - Ground 0V 1V or
other signal measurement sensor more
circuit connector.
• Key switch “ON”

On-board check procedure for sensors Name

1. Coupling connector between engine — the
3 machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
2 1
harness. Check from step 1 again.
4 • If only step 1 is faulty, replace the sensor.

TSWG0197
 Electronic control fuel injection system (Common rail type) 1E-431
DTC: P0380 (Flash code 66) Glow relay circuit fault
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

(100A)*

Starter
B

Battery B

Generator

(15A)*

(60A)*

Glow Starter Starter

relay cut relay cut relay Main relay

(10A)*
1 H-22

0.5
B/W
A A
B Br C B ACC Br C
(ON) (ST) (ON) (ST)
1 H-1
OFF OFF
ON ON
START START

10 E-57 Key switch 14 E-57

Glow Glow relay Engine

plug control control
module
(ECM)
Starter cut
relay signal

TSWG0072

Note: DTC set condition

The QOS circuit is the same for both the starter • Glow relay drive indication signal is unmatched
ECM control specifications and the safety relay with glow relay monitor signal.
specifications.
Action taken when DTC is set
Description of circuit
• Trouble is displayed on the monitor of the
The glow relay cuts off the power supply voltage (24 V) machine* or diagnosis lamp comes on. (* Nothing
to the glow plug, and turns “ON” when the signal from is displayed depending on the machine
ECM is input. The ECM recognizes the starter switch manufacturer)
“ON” signal, and outputs the “ON” signal to the glow
relay. Back-up mode

Main trouble symptom • No back-up operation (4HK1)

• Specified back-up value (depending on the
• Startability deteriorates at low temperatures.
machine manufacturer) (6HK1)
Preconditions when DTC is set
• Key switch input power supply voltage is 16 V or
more and 32 V or less.
1E-432 Electronic control fuel injection system (Common rail type)
Recovery from failure Following inspections are necessary to detect these
Refer to “List of diagnostic trouble code” and “About causes.
recovery from failure” in this section for recovery from • Improper connection of harness connector and
failure. ECM connector
– Poor connection of terminal from connector
The conditions to clear the MIL/DTC – Unmatched terminals are fitted.
• The present trouble turns to history trouble when – Damage of connector lock
the condition is out of the range from DTC set – Poor contact between terminal and wire
condition (recovery from failure). • Damaged harness
• The diagnosis lamp turns off when the trouble code – Visually check the harness for damage.
turns to the history trouble.
– Check the relevant items on the scan tool data
• Using the scan tool, or accelerator pedal operation display while moving the connector and the
enables to clear history trouble. harness which are related to the sensor. The
variation of the display indicates the faulty part.
Diagnostic aid
If the intermittent trouble is suspected, followings may Test description
be the cause. Numbers below indicate step numbers in the chart.
• Improper connection of harness connector 6. If the “Glow relay” displays “ON” when terminals
• Defective harness routing between the glow relay are shorted, the circuit beyond
• Worn harness cladding the relay is normal including ECM.
• Wire disconnection inside harness cladding 9. If the “Glow relay” displays “OFF” when the glow
relay is removed, the circuit beyond the relay is normal
including ECM.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
2 Is the scan tool available? — Go to Step 3. Go to Step 17.
1. Turn the key switch to ON position.
2. Check for “Glow relay” on the data display
3 using scan tool. —

Is the “Glow relay” displayed “ON”? Go to Step 4. Go to Step 5.

1. Turn the key switch to ON position.
2. Hold it for more than 10 seconds.
4 3. Check for “Glow relay” on the data display —
using scan tool.
Go to “Diagnostic
Is the “Glow relay” displayed “OFF”? aid”. Go to Step 9.
Check for installation condition of the glow
relay, ECM connector and coupling connector.
1. Check for play or looseness in the
5 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 6.
 Electronic control fuel injection system (Common rail type) 1E-433

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Remove the glow relay.
3. Short between the terminals 2 - 4 in the
glow relay installing portion using jump
6 cable. —
4. Turn the key switch to “ON”.
5. Check for “Glow relay” on the data display
using scan tool.
Is the “Glow relay” displayed “ON”? Go to Step 11. Go to Step 7.
1. Check for following in the circuit between
the fuse and the glow relay.
• Open circuit
• Short circuit to ground circuit
7 • High resistance —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 8.
1. Check for followings in the circuit between
glow relay and ECM using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
8 board check procedure for sensors”. —

• Open circuit
• Short circuit to ground circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
1. Turn the key switch to “OFF”.
2. Remove the glow relay.
3. Turn the key switch to “ON”.
9 —
4. Check for “Glow relay” on the data display
using scan tool.
Is the “Glow relay” displayed “OFF”? Go to Step 11. Go to Step 10.
1E-434 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the circuit between glow relay and
ECM for short circuit to the power supply
circuit or ignition power supply circuit
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
10 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 12. Go to Step 11.
Replace the glow relay.
11 —
Is the procedure completed? Go to Step 12. —
12 Is EMPS available? — Go to Step 13. Go to Step 14.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
13 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 15. Go to Step 14.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
14 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 15. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
15 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0380 detected? Go to Step 2. Go to Step 16.
 Electronic control fuel injection system (Common rail type) 1E-435

Step Action Value YES NO

Check if other DTC is detected.
16 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
Check for installation condition of the glow
relay, ECM connector and coupling connector.
1. Check for play or looseness in the
17 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 7.

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
8 Open circuit/ Resistance • Disconnect the 10 - FL 12 10 MΩ or 10 MΩ or
high measurement relay. connector terminal less more
resistance • Key switch “OFF” No. 1
Short circuit to Resistance • Disconnect the 10 - Ground 10 MΩ or 10 MΩ or
ground measurement relay. more less
• Key switch “OFF”
10 Short circuit to Voltage • Disconnect the 10 - Ground 0V 18V or
power supply measurement relay. more
circuit • Key switch “ON”
1E-436 Electronic control fuel injection system (Common rail type)
DTC: P0381 (Flash code 67) Glow plug lamp circuit fault
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

(15A)*

A A

Meter
Tachometer
Boost
Diagnosis Engine oil QOS indicator Charge
Machine trouble temperature O/H lamp
lamp pressure lamp lamp lamp
diagnosis monitor lamp

3 H-6

1 E-164

Machine
control unit O/H switch

CAN LOW CAN HIGH

Generator

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

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

Tachometer signal
CAN HIGH CAN LOW

TSHK0022

Description of circuit DTC set condition

The QOS indicator lamp is installed in the meter. The • Glow lamp indication signal is unmatched with
engine control module (ECM) turns the QOS indicator glow lamp monitor signal.
lamp on to tell the glow plug operation when the key
switch is turned “ON”. The ECM detects the glow plug Action taken when DTC is set
operating condition, and turns the lamp off upon • Trouble is displayed on the monitor of the
completion of preheat. machine* or diagnosis lamp comes on. (* Nothing
is displayed depending on the machine
Main trouble symptom manufacturer)
Operationality is not affected.
Back-up mode
Preconditions when DTC is set • Back-up: No back-up action
• Key switch input voltage is 18V or more.
• DTC P0381 is not detected. Recovery from failure
Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
failure.
 Electronic control fuel injection system (Common rail type) 1E-437
The conditions to clear the MIL/DTC – Unmatched terminals are fitted.
• The present trouble turns to history trouble when – Damage of connector lock
the condition is out of the range from DTC set – Poor contact between terminal and wire
condition (recovery from failure). • Damaged harness
• The diagnosis lamp will go off after the code turns – Visually check the harness for damage.
to history trouble and the key switch is turned – Check the relevant items on the scan tool data
“OFF” then “ON” again. display while moving the connector and the
• Using the scan tool, or memory clear switch and harness which are related to the sensor. The
diagnostic switch operation enables to clear DTCs. variation of the display indicates the faulty part.

Diagnostic aid Test description

If the intermittent trouble is suspected, followings may Numbers below indicate step numbers in the chart.
be the cause. 2. If the lamp does not come on with the key switch
• Blown lamp bulb “ON”, open circuit, short circuit to the ground circuit,
• Improper connection of harness connector blown light bulb, or ECM fault is suspected.
• Defective harness routing 2. If the lamp does not go OFF, short circuit to the
ground circuit, meter circuit fault, or ECM fault is
• Worn harness cladding
suspected.
• Wire disconnection inside harness cladding 4. If the lamp goes off when the ECM connector is
Following inspections are necessary to detect these removed, the circuit beyond the ECM is normal
causes. including meter.
• Improper connection of harness connector and 7. If the lamp comes on when the lamp control terminal
ECM connector is shorted to the ground, the circuit beyond the ECM is
– Poor connection of terminal from connector normal including meter.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
1. Turn the key switch to “ON”.
2 2. Check if the QOS indicator lamp is ON. —
Does the QOS indicator lamp come on? Go to Step 3. Go to Step 7.
Turn the key switch “ON” and wait for 10
3 seconds. Does the QOS indicator lamp go — Go to “Diagnostic
OFF? aid”. Go to Step 4.
1. Turn the key switch to “OFF”.
2. Remove the connector from the ECM.
4 3. Turn the key switch to “ON”. —
4. Check if the QOS indicator lamp is ON.
Does the QOS indicator lamp go OFF? Go to Step 12. Go to Step 5.
Check for installation condition of the meter,
ECM connector and coupling connector.
1. Check for play or looseness in the
5 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 14. Go to Step 6.
1E-438 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the circuit between QOS indicator
lamp and ECM for ground short circuit
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

6 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 14. Go to Step 11.
1. Turn the key switch to “OFF”.
2. Remove the connector from the ECM.
3. Short between the QOS indicator lamp
control terminal of the ECM and the
ground using breaker box.
Refer to “Breaker box inspection
procedure”.
7 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

4. Turn the key switch to “ON”.

5. Check if the QOS indicator lamp is ON.
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.
1. Check for play or looseness in the
8 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 14. Go to Step 9.
1. Check for following in the circuit between
the fuse and the QOS indicator lamp.
• Open circuit
• Short circuit to ground circuit
9 • High resistance —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 14. Go to Step 10.
 Electronic control fuel injection system (Common rail type) 1E-439

Step Action Value YES NO

1. Check for followings in the circuit between
QOS indicator lamp and ECM using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
10 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 14. Go to Step 12.
Replace the meter.
11 —
Is the procedure completed? Go to Step 14. —
Replace the QOS indicator lamp bulb.
12 —
Is the procedure completed? Go to Step 14. —
13 Is EMPS available? — Go to Step 14. Go to Step 15.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
14 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 16. Go to Step 15.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
15 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 16. —

1E-440 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check if DTC is not detected again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
16 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is the procedure completed? Go to Step 17. —
Check if DTC is detected. (DTC for entire
Go to the related
17 engine control) — “Inspection method
Is DTC detected? by DTC”. Verify repair.

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Resistance • Remove the 11 - Ground 10 MΩ or 10 MΩ or
ground measurement meter connector. more less
• Key switch “OFF”
10 Open circuit/ Resistance • Remove the 11 - Meter connector 10 MΩ or 10 MΩ or
high measurement meter connector. QOS indicator lamp less more
resistance • Key switch “OFF” terminal
 Electronic control fuel injection system (Common rail type) 1E-441
DTC: P0487 (Flash code 44) EGR position sensor fault

Engine control
module (ECM)

CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V

B+ B+ B+

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

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

0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B

1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W

1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 W

V U

EGR position sensor/EGR motor

EGR valve

CMP sensor Common rail pressure sensor

TSHK0028

Description of circuit The ECM provides 5 V to the EGR position sensors U,

The EGR position sensor is installed inside the EGR V, and W through 5-V power supply circuit, and grounds
valve. The EGR position sensor is the hall IC type to the inside of the ECM through ground circuit. Also,
sensor and is installed to 3 locations. It detects the the EGR position sensor outputs polarity (ON/OFF) of
motor phase based on each polarity output (ON/OFF). any one of the EGR position sensors U, V, and W
The EGR position sensor includes following circuits. through respective signal circuit, to the ECM. The ECM
detects the EGR valve position by counting the number
• 5-V power supply circuit
of change in polarity.
• Ground circuit The ECM sets the DTC when all of the EGR position
• EGR position sensor U signal circuit sensors U, V, and W output “ON” or “OFF”
• EGR position sensor V signal circuit simultaneously.
• EGR position sensor W signal circuit
Main trouble symptom
Operationality is not affected.

Preconditions when DTC is set

• Main relay input voltage is 18 V or more.
• DTC P1630 or P1635 is not detected.
1E-442 Electronic control fuel injection system (Common rail type)
DTC set condition Diagnostic aid
• Input signals from EGR position sensors U, V, and If the intermittent trouble is suspected, followings may
W are all ON or all OFF for 3 seconds or more. be the cause.
• Improper connection of harness connector
Action taken when DTC is set • Defective harness routing
• Trouble is displayed on the monitor of the • Worn harness cladding
machine* or diagnosis lamp comes on. (* Nothing • Wire disconnection inside harness cladding
is displayed depending on the machine Following inspections are necessary to detect these
manufacturer) causes.
• Improper connection of harness connector and
Back-up mode
ECM connector
• Instruction to fully close EGR valve – Poor connection of terminal from connector
– Unmatched terminals are fitted.
Recovery from failure
– Damage of connector lock
Refer to “List of diagnostic trouble code” and “About
– Poor contact between terminal and wire
recovery from failure” in this section for 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
the condition is out of the range from DTC set harness which are related to the sensor. The
condition (recovery from failure). variation of the display indicates the faulty part.
• The diagnosis lamp will go off after the code turns
Test description
to history trouble and the key switch is turned
“OFF” then “ON” again. Numbers below indicate step numbers in the chart.
• Using the scan tool, or memory clear switch and 3. Check all the signal circuits of the EGR position
diagnostic switch operation enables to clear DTCs. sensors U, V, and W.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check for installation condition of the EGR
valve connector, ECM connector and coupling
connector.
1. Check for play or looseness in the
2 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 10. Go to Step 3.
 Electronic control fuel injection system (Common rail type) 1E-443

Step Action Value YES NO

1. Check for followings in the circuit between
ECM and EGR position sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
3 —
• Short circuit to EGR position sensor
ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 10. Go to Step 4.
Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
4 3. Turn the key switch to “OFF” for more than —
10 seconds, and then start the engine.
4. Warm-up the engine until the engine
coolant temperature exceeds 80°C
(176°F).
5. Check the DTC.
Go to “Diagnostic
Is DTC P0487 detected? Go to Step 5. aid”.
Replace the EGR valve (EGR position sensor).

Note:
5 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 6. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
6 3. Turn the key switch to “OFF” for more than —
10 seconds, and then start the engine.
4. Warm-up the engine until the engine
coolant temperature exceeds 80°C
(176°F).
5. Check the DTC.
Is DTC P0487 detected? Go to Step 7. Go to Step 11.
7 Is EMPS available? — Go to Step 8. Go to Step 9.
1E-444 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

8 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 10. Go to Step 9.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
9 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 10. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
10 3. Turn the key switch to “OFF” for more than —
10 seconds.
4. Warm-up the engine until the engine
coolant temperature exceeds 80°C
(176°F).
5. Check the DTC.
Is DTC P0487 detected? Go to Step 2. Go to Step 11.
Check if other DTC is detected.
11 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-445
About EGR position sensor 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.

TSWG0158

Name
1. Position sensor power supply (5 V)
2. Position sensor signal W
3. Position sensor signal V Name
4. Position sensor signal U 1. Breaker box
5. Position sensor ground 2. DMM
6. Motor drive W
7. Motor drive V
8. Motor drive U

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
3 Open circuit/ Resistance • Disconnect the 87 - EGR valve 100Ω or 10 MΩ or
high measurement EGR valve connector sensor less more
resistance connector. power supply
• Key switch “OFF” terminal
4 Short circuit to Resistance • Disconnect the 92 - 101 10 MΩ or 100Ω or
ground circuit/ measurement EGR valve 93 - 101 more less
ground connector. 94 - 101
• Key switch “OFF” 92 - Ground
93 - Ground
94 - Ground
Open circuit/ Resistance • Disconnect the 92 - EGR valve 100Ω or 10 MΩ or
high measurement EGR valve connector position less more
resistance connector. sensor signal W
• Key switch “OFF” terminal
93 - EGR valve
connector position
sensor signal V
terminal
94 - EGR valve
connector position
sensor signal U
terminal
1E-446 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

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
 Electronic control fuel injection system (Common rail type) 1E-447
DTC: P0488 (Flash code 45) EGR valve control fault

Engine control
module (ECM)

CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V

B+ B+ B+

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

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

0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B

1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W

1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 W

V U

EGR position sensor/EGR motor

EGR valve

CMP sensor Common rail pressure sensor

TSHK0028

Description of circuit Preconditions when DTC is set

The EGR motor is installed inside the EGR valve. The • DTC P1630, P1635, P0487, P0488, or P1635 is
EGR motor is the brushless DC motor, and is driven by not detected.
three phases. The EGR position sensor includes • Main relay input power supply voltage is higher
following circuits. than 20 V but lower than 32 V.
• EGR motor drive circuit U • Difference between target EGR opening angle and
• EGR motor drive circuit V actual one is 20% or less.
• EGR motor drive circuit W
The ECM drives the EGR motor through the EGR DTC set condition
motor drive circuits U, V, and W. The ECM outputs drive • Difference between target valve lift and actual
signals by the switching inside the ECM, and the motor position is more than 20% for 10 seconds or more.
rotates with the combination of three-phase signals.
Also, the valve opening angle is controlled by duty. Action taken when DTC is set
The ECM sets the DTC when the EGR motor drive duty
• Trouble is displayed on the monitor of the
is high and the difference between the target EGR
machine* or diagnosis lamp comes on. (* Nothing
position and actual EGR position is large.
is displayed depending on the machine
manufacturer)
Main trouble symptom
Operationality is not affected.
1E-448 Electronic control fuel injection system (Common rail type)
Back-up mode • Defective harness routing
• Instruction to fully close EGR valve • Worn harness cladding
• Wire disconnection inside harness cladding
Recovery from failure Following inspections are necessary to detect these
Refer to “List of diagnostic trouble code” and “About causes.
recovery from failure” in this section for recovery from • Improper connection of harness connector and
failure. ECM connector
– Poor connection of terminal from connector
The conditions to clear the MIL/DTC – Unmatched terminals are fitted.
• The present trouble turns to history trouble when – Damage of connector lock
the condition is out of the range from DTC set – Poor contact between terminal and wire
condition (recovery from failure). • Damaged harness
• The diagnosis lamp will go off after the code turns – Visually check the harness for damage.
to history trouble and the key switch is turned
– Check the relevant items on the scan tool data
“OFF” then “ON” again.
display while moving the connector and the
• Using the scan tool, or memory clear switch and harness which are related to the sensor. The
diagnostic switch operation enables to clear DTCs. variation of the display indicates the faulty part.

Diagnostic aid Test description

If the intermittent trouble is suspected, followings may Numbers below indicate step numbers in the chart.
be the cause. 5. Check all the EGR motor drive circuits U, V, and W.
• Improper connection of harness connector

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 13.
1. Perform “EGR control test” using scan
tool.
3 2. Press the “Up” “Down” soft key. ±3%
3. Check the value for “EGR position”.
Is “EGR position” within the specified value? Go to Step 4. Go to Step 5.
Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
4 2. Turn the key switch to “OFF” for more than —
10 seconds, and then start the engine.
3. Warm-up the engine until the engine
coolant temperature exceeds 80°C
(176°F).
4. Check the DTC.
Go to “Diagnostic
Is DTC P0488 detected? Go to Step 8. aid”.
 Electronic control fuel injection system (Common rail type) 1E-449

Step Action Value YES NO

1. Check for followings in the motor drive
circuit between ECM and EGR motor
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
5 —
• Open circuit
• Short circuit to ground
• Short circuit to power supply circuit or
ignition power supply circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 11. Go to Step 6.
Replace the EGR valve.

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

Is the procedure completed? Go to Step 7. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
7 3. Turn the key switch to “OFF” for more than —
10 seconds, and then start the engine.
4. Warm-up the engine until the engine
coolant temperature exceeds 80°C
(176°F).
5. Check the DTC.
Is DTC P0488 detected? Go to Step 8. Go to Step 12.
8 Is EMPS available? — Go to Step 9. Go to Step 10.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
9 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. Go to Step 10.

1E-450 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
11 3. Turn the key switch to “OFF” for more than —
10 seconds.
4. Warm-up the engine until the engine
coolant temperature exceeds 80°C
(176°F).
5. Check the DTC.
Is DTC P0488 detected? Go to Step 2. Go to Step 12.
Check if other DTC is detected.
12 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Remove the EGR valve.
2. Check the EGR valve for anchoring,
clogging, etc.
13 3. If the trouble is detected, repair as —
required.
Is the trouble detected? Go to Step 5. Go to Step 4.

About EGR valve Name

1. Position sensor power supply (5 V)
2. Position sensor signal W
3. Position sensor signal V
4. Position sensor signal U
5. Position sensor ground
6. Motor drive W
7. Motor drive V
8. Motor drive U

TSWG0158
 Electronic control fuel injection system (Common rail type) 1E-451
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

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.
Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
5 Short circuit to Voltage • Disconnect the 111 - Ground 0V 18V or
power supply measurement EGR valve 103 - Ground more
circuit connector. 110 - Ground
• Key switch “ON”
Short circuit to Resistance • Disconnect the 111 - Ground 10 MΩ or 100Ω or
ground measurement EGR valve 103 - Ground more less
connector. 110 - Ground
• Key switch “OFF”
Open circuit/ Resistance • Disconnect the 111 - EGR valve 100Ω or 10 MΩ or
high measurement EGR valve connector motor less more
resistance connector. drive U terminal
• Key switch “OFF” 103 - EGR valve
connector motor
drive V terminal
110 - EGR valve
connector motor
drive W terminal
1E-452 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

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
 Electronic control fuel injection system (Common rail type) 1E-453
DTC: P0522 (Flash code 294) Engine oil pressure sensor fault (low voltage fault, open
circuit, ground short)

Vehicle speed Engine oil pressure

sensor signal 5V 5V sensor signal
5V

CKP CKP Engine coolant

Fuel temperature Vcc
HIGH LOW temperature sensor
signal signal sensor signal signal

108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56

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

3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

2 E-98 1 E-98

Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R

37 E-57 18 E-57
4 H-6

Vehicle
speed sensor A

Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor

TSHK0030

Description of circuit Main trouble symptom

The engine oil pressure sensor detects the engine oil Operationality is not affected.
pressure. The engine oil pressure sensor is installed
near the starter motor of the cylinder block. The Preconditions when DTC is set
resistance value in the engine oil pressure sensor • Key switch input voltage is 18V or more.
changes according to the pressure. If the pressure is
• DTC P1633 is not detected.
high, the resistance becomes low; if the pressure is low,
the resistance becomes high.
DTC set condition
The engine control module (ECM) is connected to the
engine pressure sensor via power supply circuit, signal • Engine oil pressure sensor voltage is 0.1V or less
circuit and ground circuit, and energizes +5 V power for 4 seconds or more.
supply to the power supply circuit. The ECM detects the
signal voltage change in response to the change in Action taken when DTC is set
resistance according to the engine pressure sensor • Trouble is displayed on the monitor of the
pressure (If the pressure is high, the voltage becomes machine* or diagnosis lamp comes on. (* Nothing
high; if the pressure is low, the voltage becomes low) as is displayed depending on the machine
a signal. manufacturer)
1E-454 Electronic control fuel injection system (Common rail type)
Back-up mode Following inspections are necessary to detect these
• Back-up: No back-up action causes.
• Improper connection of harness connector and
Recovery from failure ECM connector
Refer to “List of diagnostic trouble code” and “About – Poor connection of terminal from connector
recovery from failure” in this section for recovery from – Unmatched terminals are fitted.
failure. – Damage of connector lock
– Poor contact between terminal and wire
The conditions to clear the MIL/DTC • Damaged harness
• The present trouble turns to history trouble when – Visually check the harness for damage.
the condition is out of the range from DTC set – Check the relevant items on the scan tool data
condition (recovery from failure). display while moving the connector and the
• Using the scan tool, or memory clear switch and harness which are related to the sensor. The
diagnostic switch operation enables to clear DTCs. variation of the display indicates the faulty part.

Diagnostic aid Test description

If the intermittent trouble is suspected, followings may Numbers below indicate step numbers in the chart.
be the cause. 3. In the case of present trouble, the “Engine oil
• Improper connection of harness connector pressure sensor” displays more than the specified
• Defective harness routing value. In this case, identify the cause by referring to
• Worn harness cladding “Diagnostic aid”.
5. If the “Engine oil pressure sensor” displays more
• Wire disconnection inside harness cladding
than the specified value when the ECT sensor
connector is removed, the circuit beyond the sensor is
normal including ECM.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 6.
Check the value for engine oil pressure sensor
using scan tool.
1. Connect the scan tool.
2. Start the engine.
3 0.1V
3. Check the value for “Engine oil pressure
sensor” using scan tool.
Is the “Engine oil pressure sensor” less than Go to “Diagnostic
the specified value? Go to Step 4. aid”.
Check for installation condition of the engine oil
pressure sensor, ECM and coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 5.
 Electronic control fuel injection system (Common rail type) 1E-455

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the engine oil pressure sensor
connector.
3. Turn the key switch to “ON”.
5 0V
4. Check the value for “Engine oil pressure
sensor” using scan tool.
Is the “Engine oil pressure sensor” more than
the specified value? Go to Step 7. Go to Step 6.
1. Check for followings in the signal circuit
between ECM and engine oil pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —

• Short circuit to engine oil pressure

sensor ground circuit
• Short circuit to ground
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 8.
Replace the engine oil pressure sensor.
7 —
Is the procedure completed? Go to Step 11. —
8 Is EMPS available? — Go to Step 9. Go to Step 10.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
9 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. Go to Step 10.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. —

1E-456 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
11 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is the DTC P0522 detected? Go to Step 2. Go to Step 12.
1. Start the engine. 1016 kPa
2. Check the display of engine oil pressure. (147.4 psi)
12
Does the display of engine oil pressure show (Displayed Go to “Diagnostic
error value? error value) Go to Step 13. aid”.
Check for installation condition of the engine oil
pressure sensor, ECM and coupling connector.
1. Check for play or looseness in the
13 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 14.
1. Check for followings in the signal circuit
between ECM and engine oil pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
14 board check procedure for sensors”. —

• Short circuit to engine oil pressure

sensor ground circuit
• Short circuit to ground
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 11. Go to Step 7.
 Electronic control fuel injection system (Common rail type) 1E-457
About engine oil pressure sensor Characteristics of engine oil pressure sensor
The output voltage of engine oil pressure sensor
changes according to the engine oil pressure. The scan
tool with CAN communication displays a fixed value
when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value if
the value of 0 kPa (0 psi) or 1088.5 kPa (157.9 psi) is
not changed.
When error occurs, error value (1016 kPa {147.4 psi})
is displayed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
1 2 3 Tech2 and scan tools with KW communication can
display both physical value and voltage.

(V)
TSWG0164 4.85

Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply

0.496

0 1088.5(157.9)
kPa(psi)
TSWG0202
1E-458 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

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Resistance • Disconnect the 67 - 79 10 MΩ or 100Ω or
ground circuit/ measurement sensor 67 - GND more less
ground connector. 80 - 79
• Key switch “OFF” 80 - GND

On-board check procedure for sensors Name

1. Coupling connector between engine — the
3 machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
2 1
harness. Check from step 1 again.
4 • If only step 1 is faulty, replace the sensor.

TSWG0197
 Electronic control fuel injection system (Common rail type) 1E-459
DTC: P0523 (Flash code 295) Engine oil pressure sensor fault (high voltage fault, short to
power supply, ground short)
(*: Specifications vary depending on each machine. Refer to the machine’s manual.)

Vehicle speed Engine oil pressure

sensor signal 5V 5V sensor signal
5V

CKP CKP Engine coolant

Fuel temperature Vcc
HIGH LOW temperature sensor
signal signal sensor signal signal

108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56

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

3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

2 E-98 1 E-98

Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R

37 E-57 18 E-57
4 H-6

Vehicle
speed sensor A

Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor

TSHK0030

Description of circuit Main trouble symptom

The engine oil pressure sensor detects the engine oil Operationality is not affected.
pressure. The engine oil pressure sensor is installed
near the starter motor of the cylinder block. The Preconditions when DTC is set
resistance value in the engine oil pressure sensor • Key switch input voltage is 18V or more.
changes according to the pressure. If the pressure is
• DTC P1633 is not detected.
high, the resistance becomes low; if the pressure is low,
the resistance becomes high.
DTC set condition
The engine control module (ECM) is connected to the
engine pressure sensor via power supply circuit, signal • Engine oil pressure sensor voltage is 4.85V or
circuit and ground circuit, and energizes +5 V power more for 4 seconds or more.
supply to the power supply circuit. The ECM detects the
signal voltage change in response to the change in Action taken when DTC is set
resistance according to the engine pressure sensor • Trouble is displayed on the monitor of the
pressure (If the pressure is high, the voltage becomes machine* or diagnosis lamp comes on. (* Nothing
high; if the pressure is low, the voltage becomes low) as is displayed depending on the machine
a signal. manufacturer)
1E-460 Electronic control fuel injection system (Common rail type)
Back-up mode Following inspections are necessary to detect these
• Back-up: No back-up action causes.
• Improper connection of harness connector and
Recovery from failure ECM connector
Refer to “List of diagnostic trouble code” and “About – Poor connection of terminal from connector
recovery from failure” in this section for recovery from – Unmatched terminals are fitted.
failure. – Damage of connector lock
– Poor contact between terminal and wire
The conditions to clear the MIL/DTC • Damaged harness
• The present trouble turns to history trouble when – Visually check the harness for damage.
the condition is out of the range from DTC set – Check the relevant items on the scan tool data
condition (recovery from failure). display while moving the connector and the
• Using the scan tool, or memory clear switch and harness which are related to the sensor. The
diagnostic switch operation enables to clear DTCs. variation of the display indicates the faulty part.

Diagnostic aid Test description

If the intermittent trouble is suspected, followings may Numbers below indicate step numbers in the chart.
be the cause. 3. In the case of present trouble, the “Engine oil
• Improper connection of harness connector pressure sensor” displays more than the specified
• Defective harness routing value. In this case, identify the cause by referring to
• Worn harness cladding “Diagnostic aid”.
5. If the “Engine oil pressure sensor” displays less than
• Wire disconnection inside harness cladding
the specified value when terminals between the engine
oil pressure sensor connector are shorted, the circuit
beyond the sensor is normal including ECM.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 15.
Check the value for engine oil pressure sensor
using scan tool.
1. Connect the scan tool.
2. Start the engine.
3 4.85V
3. Check the value for “Engine oil pressure
sensor” using scan tool.
Is the “Engine oil pressure sensor” more than Go to “Diagnostic
the specified value? Go to Step 4. aid”.
Check for installation condition of the engine oil
pressure sensor, ECM and coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 5.
 Electronic control fuel injection system (Common rail type) 1E-461

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the engine oil pressure sensor
connector.
3. Short the engine oil pressure sensor
connector signal terminal to the ground
5 terminal using jump cable. 0V
4. Turn the key switch to “ON”.
5. Check the value for “Engine oil pressure
sensor” using scan tool.
Is the “Engine oil pressure sensor” less than
the specified value? Go to Step 9. Go to Step 6.
1. Check the signal circuit between ECM and
engine oil pressure sensor for short circuit
to the power supply circuit or ignition
power supply circuit, using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —

Important:
If the engine oil pressure sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 13. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and engine oil pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 8.
1E-462 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for followings in the ground circuit
between ECM and engine oil pressure
sensor, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
8 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 10.
Replace the engine oil pressure sensor.
9 —
Is the procedure completed? Go to Step 13. —
10 Is EMPS available? — Go to Step 10. Go to Step 11.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 11.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
13 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is the DTC P0523 detected? Go to Step 2. Go to Step 14.
 Electronic control fuel injection system (Common rail type) 1E-463

Step Action Value YES NO

Check if other DTC is detected.
14 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine. 1016 kPa
2. Check the display of engine oil pressure. (147.4 psi)
15
Does the display of engine oil pressure show (Displayed Go to “Diagnostic
error value? error value) Go to Step 16. aid”.
1. Check the signal circuit between ECM and
engine oil pressure sensor for short circuit
to the power supply circuit or ignition
power supply circuit, using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
16 board check procedure for sensors”. —

Important:
If the engine oil pressure sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 13. Go to Step 17.
1. Check for followings in the signal circuit
between ECM and engine oil pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
17 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 18.
1E-464 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for followings in the ground circuit
between ECM and engine oil pressure
sensor, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
18 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 9.

About engine oil pressure sensor Characteristics of engine oil pressure sensor
The output voltage of engine oil pressure sensor
changes according to the engine oil pressure. The scan
tool with CAN communication displays a fixed value
when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value if
the value of 0 kPa (0 psi) or 1088.5 kPa (157.9 psi) is
not changed.
When error occurs, error value (1016 kPa {147.4 psi})
is displayed.
The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
1 2 3 Tech2 and scan tools with KW communication can
display both physical value and voltage.

(V)
TSWG0164 4.85

Name
1. Sensor ground
2. Sensor signal
3. Sensor power supply

0.496

0 1088.5(157.9)
kPa(psi)
TSWG0202
 Electronic control fuel injection system (Common rail type) 1E-465
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Voltage • Disconnect the 67 - GND 0V 18V or
power supply measurement sensor more
circuit connector.
• Key switch “ON”
7 Open circuit/ Resistance • Disconnect the 67 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector signal less more
resistance connector. terminal
• Key switch “OFF”
8 Open circuit/ Resistance • Disconnect the 79 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector ground less more
resistance connector. terminal
• Key switch “OFF”
1E-466 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

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
 Electronic control fuel injection system (Common rail type) 1E-467
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 “List of diagnostic trouble code” and “About
ECM is detected. 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
• ROM fault is detected. condition (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. (* Nothing diagnostic switch operation enables to clear DTCs.
is displayed depending on the machine
manufacturer)

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2 2. Turn the key switch to “OFF” for more than —
10 seconds.
3. Test run with the “Preconditions when
DTC is set”.
4. Check the DTC.
Go to “Diagnostic
Is DTC P0601 detected? Go to Step 3. aid”.
3 Is EMPS available? — Go to Step 4. Go to Step 5.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
4 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 6. Go to Step 5.

1E-468 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
5 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 6. —

Check if other DTC is detected.
6 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-469
DTC: P0603 (Flash code 54) EEPROM fault

Description of circuit Back-up mode

The internal part of the ECM consists of ROM, • Back-up: No back-up action
EEPROM, CPU, and Sub-CPU, which perform data
storage, data clear and various controls. Recovery from failure
The ECM sets the DTC when the EEPROM fault inside Refer to “List of diagnostic trouble code” and “About
the ECM is detected. recovery from failure” in this section for recovery from
failure.
Main trouble symptom
Operationality is not affected. 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
• EEPROM fault is detected. condition (recovery from failure).
• The diagnosis lamp will go off after the code turns
Action taken when DTC is set to history trouble and the key switch is turned
• Trouble is displayed on the monitor of the “OFF” then “ON” again.
machine* or diagnosis lamp comes on. (* Nothing • Using the scan tool, or memory clear switch and
is displayed depending on the machine diagnostic switch operation enables to clear DTCs.
manufacturer)

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2 2. Turn the key switch to “OFF” for more than —
10 seconds.
3. Test run with the “Preconditions when
DTC is set”.
4. Check the DTC.
Go to “Diagnostic
Is DTC P0603 detected? Go to Step 3. aid”.
3 Is EMPS available? — Go to Step 4. Go to Step 5.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

4 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 6. Go to Step 5.

1E-470 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
5 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 6. —

Check if other DTC is detected.
6 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-471
DTC: P0606 (Flash code 51/52) CPU fault

Description of circuit Action taken when DTC is set

The internal part of the ECM consists of ROM, • Trouble is displayed on the monitor of the
EEPROM, CPU, and Sub-CPU, which perform data machine* or diagnosis lamp comes on. (* Nothing
storage, data clear and various controls. is displayed depending on the machine
The ECM sets the DTC when the CPU fault or Sub- manufacturer)
CPU fault inside the ECM is detected.
Back-up mode
Main trouble symptom • Limited injection amount 2 (multi-injection stopped)
• Output lowering • SUB-CPU stops CPU.
• Unable to start • Limited injection amount 1

Preconditions when DTC is set Recovery from failure

• 480 msec or more has elapsed after key switch Refer to “List of diagnostic trouble code” and “About
ON. recovery from failure” in this section for recovery from
• Key switch input power supply voltage is higher failure.
than 16 V.
The conditions to clear the MIL/DTC
DTC set condition • The present trouble turns to history trouble when
• Sub-CPU detects main CPU fault in 100 msec after the condition is out of the range from DTC set
key switch ON. condition (recovery from failure).
• RUN-SUB pulse does not change for 20 msec or • The diagnosis lamp will go off after the code turns
more. to history trouble and the key switch is turned
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2 2. Turn the key switch to “OFF” for more than —
10 seconds.
3. Test run with the “Preconditions when
DTC is set”.
4. Check the DTC.
Go to “Diagnostic
Is DTC P0606 detected? Go to Step 3. aid”.
3 Is EMPS available? — Go to Step 4. Go to Step 5.
1E-472 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

4 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 6. Go to Step 5.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
5 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 6. —

Check if other DTC is detected.
6 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-473
DTC: P0611 (Flash code 34) Charge circuit fault (bank 1)

Engine control
module (ECM)
CAN LOW CAN HIGH

KWP2000

52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57

1 FL-150 7 FL-150

DLC Machine
control unit

5 FL-150 4 FL-150

CAN HIGH CAN LOW

TSHK0023

Description of circuit Preconditions when DTC is set

The charge circuit inside the ECM is the voltage • Main relay power supply voltage is 18V or more.
pressurizing circuit to apply voltage to the injector, and
is divided in to two systems (4H: 2 cylinders each, 6H: 3 DTC set condition
cylinders each). The charge circuit 1 supplies the power • When charge circuit bank 1 voltage inside ECU is
supply voltage to the injectors (4H: No. 1, 2 cylinders, low for 1.5 seconds or more.
6H: No. 1, 2, 3 cylinders). The ECM sets the DTC when
the voltage in the charge circuit 1 is excessively high or Action taken when DTC is set
excessively low.
• Trouble is displayed on the monitor of the
Main trouble symptom machine* or diagnosis lamp comes on. (* Nothing
is displayed depending on the machine
• Intense engine vibration manufacturer)
• Rough idling
• Output lowering Back-up mode
• Engine blow up fault • Common 1 stop (#1, #4 cylinders stopped), EGR
• Engine stall possible stopped (4HK1)
• Common 1 stop (#1, #2, #3 cylinders stopped),
EGR stopped (6HK1)
1E-474 Electronic control fuel injection system (Common rail type)
Recovery from failure • The diagnosis lamp will go off after the code turns
Refer to “List of diagnostic trouble code” and “About to history trouble and the key switch is turned
recovery from failure” in this section for recovery from “OFF” then “ON” again.
failure. • Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
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
condition (recovery from failure).

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
2 Is the scan tool available? — Go to Step 3. Go to Step 12.
1. Make sure all the communication between
ECU and scan tool is normal.
2. Make sure the system which require
3 programming operates normally. —
3. Check the DTC.
Is DTC P0611 detected? Go to Step 4. Go to Step 10.
1. Check for followings in the ground circuit
between ECM terminals (1, 3, 4, 43, 62,
81) and ECM ground terminal (E2) using
breaker box or DMM.
4 • Open circuit —
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 10. Go to Step 5.
1. Turn the key switch to “OFF”.
2. Remove the ECM ground terminal (E2).
3. Check the ECM ground terminal (E2) for
5 intermittent trouble or poor contact. —
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 10. Go to Step 6.
1. Turn the key switch to “OFF”.
2. Remove the ECM.
3. Check the ECM terminals (1, 3, 4, 43, 62,
6 81) for intermittent trouble or poor contact. —
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 10. Go to Step 7.
7 Is EMPS available? — Go to Step 8. Go to Step 9.
 Electronic control fuel injection system (Common rail type) 1E-475

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

8 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 10. Go to Step 9.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
9 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 10. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
10 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0611 detected? Go to Step 2. Go to Step 11.
Check if other DTC is detected.
11 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
12 Is DTC P0611 detected? — Go to Step 4. Go to Step 10.
1E-476 Electronic control fuel injection system (Common rail type)
DTC: P0612 (Flash code 34) Charge circuit fault (bank 2)

Engine control
module (ECM)
CAN LOW CAN HIGH

KWP2000

52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57

1 FL-150 7 FL-150

DLC Machine
control unit

5 FL-150 4 FL-150

CAN HIGH CAN LOW

TSHK0023

Description of circuit Preconditions when DTC is set

The charge circuit inside the ECM is the voltage • Main relay power supply voltage is 18V or more.
pressurizing circuit to apply voltage to the injector, and
is divided in to two systems (4H: 2 cylinders each, 6H: 3 DTC set condition
cylinders each). The charge circuit 2 supplies the power • When ECU charge circuit bank 2 voltage is low for
supply voltage to the injectors (4H: No. 3, 4 cylinders, 1.5 seconds or more.
6H: No. 4, 5, 6 cylinders). The ECM sets the DTC when
the voltage in the charge circuit 2 is excessively high or Action taken when DTC is set
excessively low.
• ECM turns the diagnosis lamp ON.
Main trouble symptom
Back-up mode
• Intense engine vibration
• Common 2 stop (#2, #3 cylinders stopped), EGR
• Rough idling
stopped (4HK1)
• Output lowering
• Common 2 stop (#4, #5, #6 cylinders stopped),
• Engine blow up fault EGR stopped (6HK1)
• Engine stall possible
 Electronic control fuel injection system (Common rail type) 1E-477
Recovery from failure • The diagnosis lamp will go off after the code turns
Refer to “List of diagnostic trouble code” and “About to history trouble and the key switch is turned
recovery from failure” in this section for recovery from “OFF” then “ON” again.
failure. • Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
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
condition (recovery from failure).

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
2 Is the scan tool available? — Go to Step 3. Go to Step 12.
1. Make sure all the communication between
ECU and scan tool is normal.
2. Make sure the system which require
3 programming operates normally. —
3. Check the DTC.
Is DTC P0612 detected? Go to Step 4. Go to Step 10.
1. Check for followings in the ground circuit
between ECM terminals (1, 3, 4, 43, 62,
81) and ECM ground terminal (E2) using
breaker box or DMM.
4 • Open circuit —
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 10. Go to Step 5.
1. Turn the key switch to “OFF”.
2. Remove the ECM ground terminal (E2).
3. Check the ECM ground terminal (E2) for
5 intermittent trouble or poor contact. —
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 10. Go to Step 6.
1. Turn the key switch to “OFF”.
2. Remove the ECM.
3. Check the ECM terminals (1, 3, 4, 43, 62,
6 81) for intermittent trouble or poor contact. —
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 10. Go to Step 7.
7 Is EMPS available? — Go to Step 8. Go to Step 9.
1E-478 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

8 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 10. Go to Step 9.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
9 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 10. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
10 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0612 detected? Go to Step 2. Go to Step 11.
Check if other DTC is detected.
11 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
12 Is DTC P0612 detected? — Go to Step 4. Go to Step 10.
 Electronic control fuel injection system (Common rail type) 1E-479
DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

(15A)*

A A

Meter
Tachometer
Boost
Diagnosis Engine oil QOS indicator Charge
Machine trouble temperature O/H lamp
lamp pressure lamp lamp lamp
diagnosis monitor lamp

3 H-6

1 E-164

Machine
control unit O/H switch

CAN LOW CAN HIGH

Generator

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

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

Tachometer signal
CAN HIGH CAN LOW

TSHK0022

Description of circuit Preconditions when DTC is set

The power supply voltage is supplied to the diagnosis • Key switch input voltage is 18V or more.
lamp via key switch, and the signal from ECM will turn • DTC P0650 is not detected.
the lamp on. The ECM turns the diagnosis lamp on
during lamp check with the key switch “ON” and when DTC set condition
DTC is detected. Also when the diagnosis connector is
• No diagnosis lamp monitor signal exists for 1.5
connected, it blinks the diagnosis lamp according to the
seconds or more.
DTC detected. A monitor circuit is provided inside the
ECM to monitor the lamp operation.
Back-up mode
The ECM sets the DTC when the output to the
diagnosis lamp does not match with the check engine • Back-up: No back-up action
lamp operation.
Recovery from failure
Main trouble symptom Refer to “List of diagnostic trouble code” and “About
Operationality is not affected. recovery from failure” in this section for recovery from
failure.
1E-480 Electronic control fuel injection system (Common rail type)
The conditions to clear the MIL/DTC – Damage of connector lock
• The present trouble turns to history trouble when – Poor contact between terminal and wire
the condition is out of the range from DTC set • Damaged harness
condition (recovery from failure). – Visually check the harness for damage.
• The diagnosis lamp will go off after the code turns – Check the relevant items on the scan tool data
to history trouble and the key switch is turned display while moving the connector and the
“OFF” then “ON” again. harness which are related to the sensor. The
• Using the scan tool, or memory clear switch and variation of the display indicates the faulty part.
diagnostic switch operation enables to clear DTCs.
Test description
Diagnostic aid Numbers below indicate step numbers in the chart.
If the intermittent trouble is suspected, followings may 2. If the lamp does not come on with the key switch
be the cause. “ON”, open circuit, short circuit to the ground circuit,
• Improper connection of harness connector blown light bulb, or ECM fault is suspected.
• Defective harness routing 2. If the lamp does not go OFF, short circuit to the
ground circuit, meter circuit fault, or ECM fault is
• Worn harness cladding
suspected.
• Wire disconnection inside harness cladding 4. If the lamp goes off when the ECM connector is
Following inspections are necessary to detect these removed, the circuit beyond the ECM is normal
causes. including meter.
• Improper connection of harness connector and 7. If the lamp comes on when the lamp control terminal
ECM connector is shorted to the ground, the circuit beyond the ECM is
– Poor connection of terminal from connector normal including meter.
– Unmatched terminals are fitted.

Step Action Value YES NO

Perform the OBD system check. Perform “OBD
1 — system check”, and
Is the procedure completed?
Go to Step 2. Go to Step 2.
1. Turn the key switch to “ON”.
2 2. Check if the diagnosis lamp is ON. —
Does the diagnosis lamp come on? Go to Step 3. Go to Step 7.
Turn the key switch “ON” and wait for 30 Go to “Diagnostic
3 —
seconds. Does the diagnosis lamp go OFF? aid”. Go to Step 4.
1. Turn the key switch to “OFF”.
2. Remove the connector from the ECM.
4 3. Turn the key switch to “ON”. —
4. Check if the diagnosis lamp is ON.
Does the diagnosis lamp go OFF? Go to Step 12. Go to Step 5.
Check for installation condition of the meter,
ECM connector and coupling connector.
1. Check for play or looseness in the
5 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 16. Go to Step 6.
 Electronic control fuel injection system (Common rail type) 1E-481

Step Action Value YES NO

1. Check the circuit between diagnosis lamp
and ECM for ground short circuit using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

6 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 16. Go to Step 11.
1. Turn the key switch to “OFF”.
2. Remove the connector from the ECM.
3. Short between the diagnosis lamp control
terminal of the ECM and the ground using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
7 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

4. Turn the key switch to “ON”.

5. Check if the diagnosis lamp is ON.
Does the diagnosis lamp come on? Go to Step 13. Go to Step 8.
Check for installation condition of the meter,
ECM connector and coupling connector.
1. Check for play or looseness in the
8 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 16. Go to Step 9.
1. Check for following in the circuit between
the fuse and the diagnosis lamp.
• Open circuit
• Short circuit to ground circuit
9 • High resistance —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 16. Go to Step 10.
1E-482 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for followings in the circuit between
diagnosis lamp and ECM using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
10 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 16. Go to Step 12.
Replace the meter.
11 —
Is the procedure completed? Go to Step 16. —
Replace the diagnosis lamp bulb.
12 —
Is the procedure completed? Go to Step 16. —
13 Is EMPS available? — Go to Step 14. Go to Step 15.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
14 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 16. Go to Step 15.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
15 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 16. —

 Electronic control fuel injection system (Common rail type) 1E-483

Step Action Value YES NO

Check if DTC is not detected again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
16 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is the procedure completed? Go to Step 17. —
Check if DTC is detected. (DTC for entire
Go to the related
17 engine control) — “Inspection method
Is DTC detected? by DTC”. Verify repair.

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Resistance • Remove the 6 - Ground 10 MΩ or 100Ω or
ground measurement meter connector. more less
• Key switch “OFF”
10 Open circuit/ Resistance • Remove the 6 - Meter connector 100Ω or 10 MΩ or
high measurement meter connector. diagnosis lamp less more
resistance • Key switch “OFF” terminal
1E-484 Electronic control fuel injection system (Common rail type)
DTC: P1093 (Flash code 227) No pump pressure feed

2 4HK1

3
1

6
7

5 6HK1

TSHK0041

Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
 Electronic control fuel injection system (Common rail type) 1E-485

Engine control
module (ECM)

CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V

B+ B+ B+

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

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

0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B

1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W

1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 W

V U

EGR position sensor/EGR motor

EGR valve

CMP sensor Common rail pressure sensor

TSHK0028

Description of circuit Main trouble symptom

The supply pump sucks fuel from the fuel tank using the • Intense engine vibration
trochoid-type feed pump located inside of the supply • Rough idling
pump. The sucked fuel is sent through the SCV to the • Output lowering
two plungers located inside the supply pump, and is
• Engine blow up fault
pressurized and sent to the common rail. The SCV
opening angle controls the fuel flow; if the SCV drive • Black smoke emitted
duty is large, the SCV opening angle becomes small • Engine stall
resulting in less fuel flow. The ECM drives the SCV by
calculating the target common rail pressure, target fuel
flow, etc. based on the information from each sensor.
The ECM sets the DTC when the SCV drive duty, or the
target fuel flow and target common rail pressure exceed
certain amount.
1E-486 Electronic control fuel injection system (Common rail type)
Fuel system filter

:Desired rail puressure

4
3 :Actual rail presure

Absolute pressure
5

30MPa(4351psi)

Actual 1 P1093
2
t2 > 5sec

t1 > 3sec
15MPa Actual 2
(2176psi) P0087

TSHK0130
1
TSHK0039
Action taken when DTC is set
Name • Trouble is displayed on the monitor of the
1. Fuel pump strainer machine* or diagnosis lamp comes on. (* Nothing
2. Pre-fuel filter is displayed depending on the machine
3. Electromagnetic pump filter manufacturer)
4. Main fuel filter
5. Gauze filter Back-up mode
Filter clogging in the fuel system may establish the DTC • Limited injection amount 3 (multi-injection stopped)
set condition. Check as required. • Target RP upper limit (80 MPa {11603 psi})

Preconditions when DTC is set Recovery from failure

• Key switch input voltage is 18V or more. Refer to “List of diagnostic trouble code” and “About
• DTC P0192, P0193, P1093, P0090, P1291, recovery from failure” in this section for recovery from
P1292, or P1635 is not detected. failure.
• Coolant temperature is 60°C (140°F) or more, and
375 rpm or more. 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
• Duty to SCV is 33% or less. condition (recovery from failure).
• Differential pressure feed is 28000 mm3/sec (1.7 • The diagnosis lamp will go off after the code turns
cu⋅in/sec) or more. to history trouble and the key switch is turned
Either of the above conditions and the following “OFF” then “ON” again.
condition • Using the scan tool, or memory clear switch and
At 1200 rpm or more, actual rail pressure is 30 diagnostic switch operation enables to clear DTCs.
MPa (4351 psi) or more lower than target rail
pressure for 5 seconds or more. Diagnostic aid
Followings are suspected as the cause.
• Injector internal trouble
• Supply pump internal trouble
• Fuel system pipe fault (fuel leakage, clogging,
crush, etc.)
• Fuel filter fault (clogging)
• Fuel tank fault (clogging)
• Pressure limiter trouble (operation under specified
pressure, degradation of sealability)
• ECM trouble
• Common rail pressure sensor trouble
 Electronic control fuel injection system (Common rail type) 1E-487
Test description
Numbers below indicate step numbers in the chart.
4. When rise of fuel level or diesel fuel odor is
confirmed, fuel leakage in the injector portion may be
the cause of the DTC detection.
10. If the “Common rail pressure sensor” displays more
than the specified value when the common rail
pressure sensor connector is removed, the circuit
beyond the sensor is normal including ECM.
Step Action Value YES NO
Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check the fuel system in the following
procedure.
1. Check the high pressure pipe and low
pressure pipe for looseness in the
connection (fuel leakage), crush or
clogging.
Check the clogging in the following
procedure.
• Fuel filter (main fuel filter, pre-fuel filter,
2 gauze filter) —
• Fuel tank (pump strainer)
• Fuel system pipe
2. Check the fuel pipe, fuel filter, and inside
of the fuel tank for freeze or waxing. (at
cold temperature)
3. Check the feed pipe inside the fuel tank for
clogging of foreign matter.
Is the fuel system normal? Go to Step 4. Go to Step 3.
Check the electromagnetic pump.
1. Inspect the electromagnetic pump by
referring to the “Electromagnetic pump
3 inspection procedure”. —
2. Repair or replace the faulty part.
Is the procedure completed? Go to Step 5. —
Check for rise of fuel level in the oil level gauge
4 or light oil odor. —
Is the trouble detected? Go to Step 5. Go to Step 6.
Check the connection of the fuel pipe in each
injector, and replace the injector if oil leakage is
confirmed.

5 Note: —
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? Go to Step 17. —

Is the scan tool (KW communication)
6 —
available? Go to Step 7. Go to Step 20.
1E-488 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the injector.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2. Start the engine.
3. Select the “Actuator test” from the menu.
7 —
4. Select the “Injection stop at each injector”
in the “Common rail system”.
5. Press the “OFF” soft key to stop the fuel
injection in the cylinder one by one, and
check the change in engine sound.
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 8. Go to Step 9.
1. Replace the injector in the cylinder of
which engine sound did not change when
it is stopped in step 9.

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

Is the procedure completed? Go to Step 18. —

Check the common rail pressure.
1. Turn the key switch to “ON”.
2. Check for “Common rail pressure” on the
data display using scan tool.
At engine
3. Start the engine and run it at idle. stopping:
4. Check for “Common rail pressure” on the −30 MPa (−
9 data display using scan tool. 4351 psi); At
5. Race it quickly for about 5 times. idling, racing:
6. Check for “Common rail pressure” on the ±5 MPa (±725
data display using scan tool. psi)

Is each value of “Common rail pressure” (at

engine stopped, idling and racing) around
specified value? Go to Step 16. Go to Step 10.
1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Turn the key switch to “ON”.
10 4.8V
4. Check for “Common rail pressure sensor”
on the data display using scan tool.
Is the “Common rail pressure sensor” more
than the specified value? Go to Step 15. Go to Step 11.
 Electronic control fuel injection system (Common rail type) 1E-489

Step Action Value YES NO

1. Check the signal circuit between common
rail pressure sensor and ECM for short
circuit to signal circuits of other sensors
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
11 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 18. Go to Step 12.
12 Is EMPS available? — Go to Step 13. Go to Step 14.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
13 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 18. Go to Step 14.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
14 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 18. —

Replace the common rail (common rail
pressure sensor).

Note:
15 —
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? Go to Step 18. —

1E-490 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2. Start the engine.
3. Select the “Actuator test” from the menu. ±5 MPa
16
4. Select the “Rail pressure control” in the (±725 psi)
“Common rail system”.
5. Press the “Up” soft key to check the value
of “Common rail pressure”.
Is “Common rail pressure” within the specified
value? Go to Step 18. Go to Step 17.
Replace the supply pump.

Note:
17 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 18. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
18 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1093 detected? Go to Step 2. Go to Step 19.
Check if other DTC is detected.
19 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
Check the injector using injector checker.
Refer to “How to use injector checker” in this
section for how to use injector checker.
20 —
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 8. Go to Step 11.
 Electronic control fuel injection system (Common rail type) 1E-491
About common rail pressure sensor

1
2

3 2 1
3

TSHK0106

TSWG0055 Name
Name 1. Electromagnetic Pump
1. Sensor ground 2. + terminal
2. Sensor signal 3. − terminal
3. Sensor power supply
3. Blow air into the inlet of the electromagnetic pump
with your mouth.
Electromagnetic pump inspection procedure • The internal seal may be stuck. Blow air to
1. Turn the key switch to ON, and check for pulsation eliminate sticking.
in the fuel hose.
• It is normal if pulsation exists.
2. Disconnect the electromagnetic pump connector,
and connect 24V power supply to the 2
electromagnetic pump side to check if the pump
operates.
• If it operates properly, there may be open
circuit, short circuit or poor contact in the
machine-side harness. Repair the faulty part,
and check again from Step 1.
• If the electromagnetic pump does not operate,
replace the pump. 1

TSHK0107

Name
1. Fuel inlet port
2. Fuel outlet port

4. Install the removed parts, and check again from

Step 1.
1E-492 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

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
11 Short circuit to Voltage • Disconnect the 82 - Ground 0V 1V or
other signal measurement sensor 90 - Ground more
circuit connector.
• Key switch “ON”

On-board check procedure for sensors Name

1. Coupling connector between engine — the
3 machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
2 1
harness. Check from step 1 again.
4 • If only step 1 is faulty, replace the sensor.

TSWG0197
 Electronic control fuel injection system (Common rail type) 1E-493
DTC: P1095 (Flash code 225) Pressure limiter open

2 4HK1

3
1

6
7

5 6HK1

TSHK0041

Name
1. Common rail 5. Fuel tank
2. Fuel filter 6. Supply pump
3. Electromagnetic Pump 7. Injector
4. Pre-filter
1E-494 Electronic control fuel injection system (Common rail type)

Engine control
module (ECM)

CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V

B+ B+ B+

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

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

0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B

1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W

1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 W

V U

EGR position sensor/EGR motor

EGR valve

CMP sensor Common rail pressure sensor

TSHK0028

Description of circuit Main trouble symptom

The supply pump sucks fuel from the fuel tank using the • Output lowering
trochoid-type feed pump located inside of the supply • Hunting
pump. The sucked fuel is sent through the SCV to the
two plungers located inside the supply pump, and is
pressurized and sent to the common rail. The SCV
opening angle controls the fuel flow; if the SCV drive
duty is large, the SCV opening angle becomes small
resulting in less fuel flow. The ECM drives the SCV by
calculating the target common rail pressure, target fuel
flow, etc. based on the information from each sensor.
The ECM sets the DTC when the common rail pressure
increases to certain level then lowers sharply, as it
recognizes that the pressure limiter is activated.
 Electronic control fuel injection system (Common rail type) 1E-495
Fuel system filter

4
3

Common rail
presure
T>1sec=P1095

5 200 MPa
(29008psi)

190 MPa T
(27557psi)
185 MPa
2 (26832psi)

T
T>5sec=P0088

TSHK0043
1
TSHK0039
Action taken when DTC is set
Name • Turns the diagnosis lamp ON.
1. Fuel pump strainer
2. Pre-fuel filter Back-up mode
3. Electromagnetic pump filter
4. Main fuel filter • Limited injection amount 1
5. Gauze filter • Output goes down to about 50% since fuel flow is
limited.
Filter clogging in the fuel system may establish the DTC
set condition. Check as required. Recovery from failure
Refer to “List of diagnostic trouble code” and “About
Preconditions when DTC is set
recovery from failure” in this section for recovery from
• Key switch input voltage is 18V or more. failure.
• DTC P1095, P0192, P0193, P1630, or P1635 is
not detected. The conditions to clear the MIL/DTC
• 50 rpm or more • The present trouble turns to history trouble when
the condition is out of the range from DTC set
DTC set condition condition (recovery from failure).
• When pressure limiter is opened. • The diagnosis lamp will go off after the code turns
• When common rail pressure is more than 200 MPa to history trouble and the key switch is turned
(29008 psi) for 1 second or more. “OFF” then “ON” again.
• DTC set condition in the case of high common rail • Using the scan tool, or memory clear switch and
pressure is described below. diagnostic switch operation enables to clear DTCs.
Only P1095 is detected if the fuel pressure
overshoots due to entry of air. Diagnostic aid
Followings are suspected as the cause.
• Air mixed in the high-pressure fuel pipe.
• Injector internal trouble
• Supply pump internal trouble
• Fuel system pipe fault (clogging etc.)
• Fuel filter fault (temporary clogging due to waxing
at low temperatures, improper tightening of filter
cartridge, etc.)
• Fuel tank fault (temporary clogging, air mixed due
to fuel shortage, air mixed due to modified fuel pipe
for additional tank etc.)
1E-496 Electronic control fuel injection system (Common rail type)
• Pressure limiter trouble (operation under specified Test description
pressure, degradation of sealability) Numbers below indicate step numbers in the chart.
• ECM trouble 8. If the “Common rail pressure sensor” displays more
• Common rail pressure sensor trouble than the specified value when the common rail
• Running out of fuel pressure sensor connector is removed, the circuit
beyond the sensor is normal including ECM.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check the DTC again.
1. Check and record the DTC.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
3. Check the fuel amount, and add fuel as
required. If fuel is low, P1095 may be
detected due to entry of air.
• If air bleeding is insufficient, overshoot
exceeds 200 MPa (29008 psi) and
2 DTC will be detected. —

Note:
• Bleeding air from fuel must be
performed correctly, following the
procedure.
• For work procedure, refer to “Engine
section” in the service manual.

4. Bleed air from the fuel.

5. Race it quickly for about 5 times.
6. Check the DTC. Refer to
“Diagnostic aid”
Is DTC P1095 detected? Go to Step 3. and Go to Step 4.
Narrow down the cause.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
3 2. Connect another pipe to the supply pump —
inlet duct, and test run while supplying
fuel. (At this time, replace the fuel hose
with a transparent hose to visually check
for air mixture in the fuel.)
3. Check the DTC.
Is DTC P1095 detected? Go to Step 16. Go to Step 4.
 Electronic control fuel injection system (Common rail type) 1E-497

Step Action Value YES NO

Check the fuel system in the following
procedure.
1. Check the high pressure pipe and low
pressure pipe for looseness in the
connection (fuel leakage), crush or
clogging.
Check the clogging in the following
procedure.
• Fuel filter (main fuel filter, pre-fuel filter,
4 gauze filter) —
• Fuel tank (pump strainer)
• Fuel system pipe
2. Check the fuel pipe, fuel filter, and inside
of the fuel tank for freeze or waxing. (at
cold temperature)
3. Check the feed pipe inside the fuel tank for
clogging of foreign matter.
Is the fuel system normal? Go to Step 6. Go to Step 5.
Repair or replace the faulty part.
5 —
Is the procedure completed? Go to Step 17. —
Is the scan tool (KW communication)
6 —
available? Go to Step 7. Go to Step 20.
Check the common rail pressure.
1. Turn the key switch to “ON”.
2. Check for “Differential fuel rail pressure”
on the data display using scan tool.
At engine
3. Start the engine and run it at idle. stopping:
4. Check for “Differential fuel rail pressure” −30 MPa (−
7 on the data display using scan tool. 4351 psi); At
5. Race it quickly for about 5 times. idling, racing:
6. Check for “Differential fuel rail pressure” ±5 MPa (±725
on the data display using scan tool. psi)

Is each value of “Fuel rail pressure” (at engine

stopped, idling and racing) around the
specified value? Go to Step 14. Go to Step 8.
1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Turn the key switch to “ON”.
8 0V
4. Check for “Common rail pressure sensor”
on the data display using scan tool.
Is the “Common rail pressure sensor” specified
value? Go to Step 13. Go to Step 9.
1E-498 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the signal circuit between common
rail pressure sensor and ECM for short
circuit to signal circuits of other sensors
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
9 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 18. Go to Step 10.
10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 12.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

Replace the common rail (common rail
pressure sensor).

Note:
13 —
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? Go to Step 18. —

 Electronic control fuel injection system (Common rail type) 1E-499

Step Action Value YES NO

Check the DTC again.
1. Restore the machine.
2. Bleed air from the fuel.
3. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
14 diagnosis” in this section for how to clear —
DTCs.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1095 detected? Go to Step 15. Go to Step 19.
1. Replace the common rail.

Note:
For work procedure, refer to “Engine
section” in the service manual.

2. Bleed air from the fuel.

3. Clear the DTC.
15 Refer to “How to clear diagnosis trouble —
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1095 detected? Go to Step 16. Go to Step 18.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2. Start the engine.
If Tech2 is available, go to step 3.
If Tech2 is not available, go to step 17. ±5 MPa (±725
16
3. Select the “Actuator test” from the menu. psi)
4. Select the “Rail pressure control” in the
“Common rail system”.
5. Press the “Up” soft key to check the value
of “Differential fuel pressure”.
Is “Differential fuel rail pressure” within the
specified value? Go to Step 18. Go to Step 17.
Replace the supply pump.

Note:
• Bleed air completely after the parts are
replaced. If air bleeding is not
17 sufficient, P1095 may be detected due —
to overshoot of fuel pressure.
• For work procedure, refer to “Engine
section” in the service manual.
Is the procedure completed? Go to Step 18. —
1E-500 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
18 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1095 detected? Go to Step 2. Go to Step 19.
Check if other DTC is detected.
19 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Turn the key switch to “ON”.
4. Connect the DMM between the common
rail pressure sensor connector signal
terminal and the ground.
20 0V
Is the DMM indication specified value?

Note:
If the display of DMM is not specified value,
ECM side wiring, wrap-around in ECM or
short circuit may be the cause.
If it is specified value, ECM side wiring is
normal. Go to Step 13. Go to Step 9.

About common rail pressure sensor Name

1. Sensor ground
2. Sensor signal
3. Sensor power supply

3 2 1

TSWG0055
 Electronic control fuel injection system (Common rail type) 1E-501
Characteristics of common rail pressure sensor Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
(V) step. After inspection, return to the diagnostic step.
4.2

0 200(29008)
MPa(psi)
TSWG0201

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
9 Short circuit to Voltage • Disconnect the 82 - Ground 0V 1V or
other signal measurement sensor 90 - Ground more
circuit connector.
• Key switch “ON”

On-board check procedure for sensors Name

1. Coupling connector between engine — the
3
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
1
harness. Check from step 1 again.
2
4 • If only step 1 is faulty, replace the sensor.

TSWG0197
1E-502 Electronic control fuel injection system (Common rail type)
DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground
short)

Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal

74 E-56 109 E-56 91 E-56 95 E-56

15 H-20 17 H-20 16 H-20 8 H-20

0.75 0.75 0.75 0.75 0.75

B/R R/L R/L L R/W

2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

Boost temperature sensor

Boost pressure sensor

TSWG0079

Description of circuit Preconditions when DTC is set

The boost temperature sensor is installed to the intake • Key switch input voltage is 18V or more.
manifold. The resistance value of boost temperature • DTC P1634 is not detected.
sensor changes according to the temperature in intake
manifold. DTC set condition
The resistance is low when the intake air temperature is
• Boost temperature sensor voltage is 0.1V or less
high, and is high when the temperature is low. The
for 4 seconds or more.
ECM energizes 5 V to the boost temperature sensor
through the pull up resistance, and calculates the boost
Action taken when DTC is set
temperature from the change in voltage, to utilize
various control such as fuel injection control. If the • Turns the diagnosis lamp ON.
resistance is low (temperature is high), the voltage
becomes low; if the resistance is high (temperature is Back-up mode
low), the voltage becomes high. • Back-up: No back-up action

Main trouble symptom

Operationality is not affected.
 Electronic control fuel injection system (Common rail type) 1E-503
Recovery from failure Following inspections are necessary to detect these
Refer to “List of diagnostic trouble code” and “About causes.
recovery from failure” in this section for recovery from • Improper connection of harness connector and
failure. ECM connector
– Poor connection of terminal from connector
The conditions to clear the MIL/DTC – Unmatched terminals are fitted.
• The present trouble turns to history trouble when – Damage of connector lock
the condition is out of the range from DTC set – Poor contact between terminal and wire
condition (recovery from failure). • Damaged harness
• The diagnosis lamp will go off after the code turns – Visually check the harness for damage.
to history trouble and the key switch is turned
– Check the relevant items on the scan tool data
“OFF” then “ON” again.
display while moving the connector and the
• Using the scan tool, or memory clear switch and harness which are related to the sensor. The
diagnostic switch operation enables to clear DTCs. variation of the display indicates the faulty part.

Diagnostic aid Test description

If the intermittent trouble is suspected, followings may Numbers below indicate step numbers in the chart.
be the cause. 3. In the case of present trouble, the “Boost
• Improper connection of harness connector temperature sensor” displays less than the specified
• Defective harness routing value. If more than the specified value, identify the
• Worn harness cladding cause by referring to “Diagnostic aid”.
• Wire disconnection inside harness cladding 5. If the “Boost temperature sensor” displays more than
the specified value when terminals between the boost
temperature sensor connector are shorted, the circuit
beyond the sensor is normal including ECM.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 14.
1. Turn the key switch to “ON”.
2. Check for “Boost temperature sensor” on
3 the data display using scan tool. 0.1V
Is the “Boost temperature sensor” less than the Go to “Diagnostic
specified value? Go to Step 4. aid”.
Check for installation condition of the boost
temperature sensor connector, ECM connector
and coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 5.
1E-504 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the boost temperature sensor
connector.
3. Short between the boost temperature
sensor connector ground terminal and the
5 signal terminal using jump cable. 4.8V
4. Turn the key switch to “ON”.
5. Check for “Boost temperature” on the data
display using scan tool.
Is the “Boost temperature” more than the
specified value? Go to Step 8. Go to Step 9.
1. Check for followings in the power supply
circuit between ECM and boost
temperature sensor, using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.

Note:
6 If breaker box is not available, refer to “On- —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and boost temperature
sensor, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 —
• Short circuit to boost temperature
sensor ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the boost temperature sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
 Electronic control fuel injection system (Common rail type) 1E-505

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

10 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. Go to Step 11.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
12 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is the DTC P1112 detected? Go to Step 2. Go to Step 13.
Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine.
2. Check the display of boost temperature. 214°C (419°F)
14 (Displayed
Does the display of “Boost temperature” show error value) Go to “Diagnostic
error value? Go to Step 15. aid”.
Check for installation condition of the boost
temperature sensor connector, ECM connector
and coupling connector.
1. Check for play or looseness in the
15 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 16.
1E-506 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for followings in the power supply
circuit between ECM and boost
temperature sensor, using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.

Note:
16 If breaker box is not available, refer to “On- —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 17.
1. Check for followings in the signal circuit
between ECM and boost temperature
sensor, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
17 —
• Short circuit to boost temperature
sensor ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 8.

About boost temperature sensor Name

1. Signal
2. GND
 Electronic control fuel injection system (Common rail type) 1E-507
Characteristics of boost temperature sensor
The output voltage of boost temperature sensor
changes according to the boost temperature. The
scan tool with CAN communication displays a fixed
value when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold
value if the value of −40°C (−40°F) or 120°C (248°F)
is not changed.
When error occurs, error value (214°C {419°F}) is
displayed.
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
display both physical value and voltage.

(V)
4.9824

1.1719

-40 120
(-40) (248) F
TSWG0204

1000

100

10
Resistance

0.1

0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
1E-508 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

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Open circuit/ Resistance • Disconnect the 74 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector signal less more
resistance connector. terminal
• Key switch “OFF”
7 Short circuit to Resistance • Disconnect the 74 - 109 10 MΩ or 100Ω or
ground circuit/ measurement sensor 74 - GND more less
ground connector.
• Key switch “OFF”
Open circuit/ Resistance • Disconnect the 74 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector signal less more
resistance connector. terminal
• Key switch “OFF”
 Electronic control fuel injection system (Common rail type) 1E-509
On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
1E-510 Electronic control fuel injection system (Common rail type)
DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open
circuit, short to power supply circuit)

Boost pressure
5V sensor signal
Engine
5V control
module
(ECM)
Boost temperature
sensor signal

74 E-56 109 E-56 91 E-56 95 E-56

15 H-20 17 H-20 16 H-20 8 H-20

0.75 0.75 0.75 0.75 0.75

B/R R/L R/L L R/W

2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

Boost temperature sensor

Boost pressure sensor

TSWG0079

Description of circuit Preconditions when DTC is set

The boost temperature sensor is installed to the intake • Key switch input voltage is 18V or more.
manifold. The resistance value of boost temperature • DTC P1634 is not detected.
sensor changes according to the temperature in intake • Coolant temperature is 50°C (122°F) or more.
manifold.
• 3 (or 5) minutes have passed after engine starting
The resistance is low when the intake air temperature is
(depending on the machine manufacturer)
high, and is high when the temperature is low. The
ECM energizes 5 V to the boost temperature sensor
DTC set condition
through the pull up resistance, and calculates the boost
temperature from the change in voltage, to utilize • Boost temperature sensor voltage is 4.95V or more
various control such as fuel injection control. If the for 4 seconds or more.
resistance is low (temperature is high), the voltage
becomes low; if the resistance is high (temperature is Action taken when DTC is set
low), the voltage becomes high. • Turns the diagnosis lamp ON.

Main trouble symptom Back-up mode

Operationality is not affected. • Back-up: No back-up action
 Electronic control fuel injection system (Common rail type) 1E-511
Recovery from failure Following inspections are necessary to detect these
Refer to “List of diagnostic trouble code” and “About causes.
recovery from failure” in this section for recovery from • Improper connection of harness connector and
failure. ECM connector
– Poor connection of terminal from connector
The conditions to clear the MIL/DTC – Unmatched terminals are fitted.
• The present trouble turns to history trouble when – Damage of connector lock
the condition is out of the range from DTC set – Poor contact between terminal and wire
condition (recovery from failure). • Damaged harness
• The diagnosis lamp turns off when the trouble code – Visually check the harness for damage.
turns to the history trouble.
– Check the relevant items on the scan tool data
• Using the scan tool, or memory clear switch and display while moving the connector and the
diagnostic switch operation enables to clear DTCs. harness which are related to the sensor. The
variation of the display indicates the faulty part.
Diagnostic aid
If the intermittent trouble is suspected, followings may Test description
be the cause. Numbers below indicate step numbers in the chart.
• Improper connection of harness connector 3. In the case of present trouble, the “Boost
• Defective harness routing temperature sensor” displays more than the specified
• Worn harness cladding value. If less than the specified value, identify the cause
• Wire disconnection inside harness cladding by referring to “Diagnostic aid”.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 14.
1. Turn the key switch to “ON”.
2. Check for “Boost temperature sensor” on
3 the data display using scan tool. 4.95V
Is the “Boost temperature sensor” more than Go to “Diagnostic
the specified value? Go to Step 4. aid”.
Check for installation condition of the boost
temperature sensor connector, ECM connector
and coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 5.
1E-512 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the signal circuit between ECM and
boost temperature sensor for short circuit
to the power supply circuit or ignition
power supply circuit, using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
5 board check procedure for sensors”. —

Important:
If the boost temperature sensor circuit is
shorted to the power supply circuit, the sensor
may be broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 11. Go to Step 6.
1. Check for followings in the ground circuit
between ECM and boost temperature
sensor, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
6 If breaker box is not available, refer to “On- —
board check procedure for sensors”. Note:
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 11. Go to Step 8.
Replace the boost temperature sensor.
7 —
Is the procedure completed? Go to Step 11. —
8 Is EMPS available? — Go to Step 9. Go to Step 10.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

9 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. Go to Step 10.

 Electronic control fuel injection system (Common rail type) 1E-513

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
11 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P0238 detected? Go to Step 2. Go to Step 12.
Check if other DTC is detected.
12 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Start the engine.
2. Check the display of boost temperature. 214°C (419°F)
13 (Displayed
Does the display of “Boost temperature” show error value) Go to “Diagnostic
error value? Go to Step 14. aid”.
Check for installation condition of the boost
temperature sensor connector, ECM connector
and coupling connector.
1. Check for play or looseness in the
14 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 11. Go to Step 15.
1. Check for followings in the ground circuit
between ECM and boost temperature
sensor, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
15 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 11. Go to Step 7.
1E-514 Electronic control fuel injection system (Common rail type)
About boost temperature sensor Characteristics of boost temperature sensor
The output voltage of boost temperature sensor
changes according to the boost temperature. The scan
tool with CAN communication displays a fixed value
when the value exceeds the threshold voltage.
Therefore, judge as it is more than the threshold value if
the value of −40°C (−40°F) or 120°C (248°F) is not
changed.
When error occurs, error value (214°C {419°F}) is
displayed.
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
display both physical value and voltage.

(V)
4.9824

Name
1. Signal
2. GND

1.1719

-40 120
(-40) (248) F
TSWG0204

1000

100

10
Resistance

0.1

0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140) (158) (176) (194) (212) (230) (248) (266) (284) (302)
Temperature
TSWG0060
 Electronic control fuel injection system (Common rail type) 1E-515
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
5 Short circuit to Voltage • Disconnect the 74 - GND 0V 18V or
power supply measurement sensor more
circuit connector.
• Key switch “ON”
6 Open circuit/ Resistance • Disconnect the 109 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector ground less more
resistance connector. terminal
• Key switch “OFF”
1E-516 Electronic control fuel injection system (Common rail type)
DTC: P1173 (Flash code 542) Overheat
(*: Specifications vary depending on each machine. Refer to the machine’s manual.)

Vehicle speed Engine oil pressure

sensor signal 5V 5V sensor signal
5V

CKP CKP Engine coolant

Fuel temperature Vcc
HIGH LOW temperature sensor
signal signal sensor signal signal

108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56

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

3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

2 E-98 1 E-98

Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R

37 E-57 18 E-57
4 H-6

Vehicle
speed sensor A

Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor

TSHK0030

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
temperature increases, the resistance becomes small,
and the voltage lowers. The ECM detects the engine
coolant temperature based on the signal from the ECT
sensor to perform various controls.
The ECM sets the DTC when it judges that the engine
coolant temperature exceed certain level based on the
signal from the ECT sensor.
 Electronic control fuel injection system (Common rail type) 1E-517
Main trouble symptom The conditions to clear the MIL/DTC
• Output lowering • The present trouble turns to history trouble when
• Fuel flow is regulated during overheat when the the condition is out of the range from DTC set
temperature exceeds 108°C (226°F). condition (recovery from failure).
• The diagnosis lamp will go off after the code turns
to history trouble and the key switch is turned
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.

(226 )
Diagnostic aid
100%
If the intermittent trouble is suspected, followings may
be the cause.
• Improper connection of harness connector
Fuel fiow

(248 ) • Defective harness routing

• Worn harness cladding
• Wire disconnection inside harness cladding
Following inspections are necessary to detect these
causes.
(221 )
Engine coolant temperature
• Improper connection of harness connector and
ECM connector
TSWG0169
– Poor connection of terminal from connector
Preconditions when DTC is set – Unmatched terminals are fitted.
– Damage of connector lock
• Key switch input voltage is 18V or more.
– Poor contact between terminal and wire
• DTC P1630, P1633, P0117, or P0118 is not
detected. • Damaged harness
• Engine under operation – Visually check the harness for damage.
– Check the relevant items on the scan tool data
DTC set condition display while moving the connector and the
harness which are related to the sensor. The
• Engine coolant temperature is more than 120°C
variation of the display indicates the faulty part.
(248°F) for 5 seconds or more.
Test description
Action taken when DTC is set
Numbers below indicate step numbers in the chart.
• Turns the diagnosis lamp ON.
4. If the “Engine coolant temperature sensor” displays
less than the specified value when the ECT sensor
Back-up mode
connector is removed, the sensor is faulty.
• Back-up: No back-up action 9. If no DTC is detected, intermittent trouble is
suspected. Identify the cause by referring to
Recovery from failure “Diagnostic aid”.
Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
failure.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Start the engine.
2 2. Check the DTC. — Go to the relevant
Is DTC P0088, or P1093 detected? DTC detected. Go to Step 3.
3 Is the scan tool available? — Go to Step 4. Go to Step 14.
1E-518 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the ECT sensor connector.
3. Turn the key switch to “ON”.
4. Check for “Engine coolant temperature 4.9V/−40°C (−
4
sensor” on the data display using scan 40°F)
tool.
Is the “Engine coolant temperature sensor”
more than the specified value? Go to Step 6. Go to Step 5.
1. Check the signal circuit between ECT
sensor and ECM for short circuit to signal
circuits of other sensors using breaker box
or DMM.
Refer to “Breaker box inspection
procedure”.
5 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 13. Go to Step 10.
1. Check the engine coolant amount.
2. If insufficient, add engine coolant.
3. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
6 diagnosis” in this section for how to clear —
DTCs.
4. Turn the key switch to “OFF” for more than
10 seconds.
5. Start the engine, and check the DTC.
Is DTC P1173 detected? Go to Step 7. Go to Step 13.
1. Check for following mechanical defects.
(Refer to “Cooling system” of “Engine
section” in the service manual.)
• Clogging of radiator
• Defective radiator cap
• Loose fan belt
7 • Defective thermostat —
• Defective water pump
• Defective cylinder head gasket
2. If the trouble is detected, adjust or replace
as required.
Is the trouble detected? Go to Step 13. Go to Step 8.
Replace the ECT sensor.
8 —
Is the procedure completed? Go to Step 13. —
 Electronic control fuel injection system (Common rail type) 1E-519

Step Action Value YES NO

Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
9 2. Turn the key switch to “OFF” for more than —
10 seconds.
3. Test run with the “Preconditions when
DTC is set”.
4. Check the DTC.
Go to “Diagnostic
Is DTC P1173 detected? Go to Step 10. aid”.
10 Is EMPS available? — Go to Step 11. Go to Step 12.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
11 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 12.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Turn the key switch to “OFF”.
2. Disconnect the ECT sensor connector.
3. Turn the key switch to “ON”.
−40°C
14 4. Check the display of the “Engine coolant
(−40°F)
temperature”.
Is the “Engine coolant temperature” more than
the specified value? Go to Step 6. Go to Step 5.
1E-520 Electronic control fuel injection system (Common rail type)
About ECT sensor The following illustration shows the correlation between
physical value and voltage displayed in the scan tools
with CAN communication.
2 1 Tech2 and scan tools with KW communication can
display both physical value and voltage.

(V)

4.7441
3

1 2 3

TSWG0061
0.2129
Name
-40 120
1. Sensor GND (for engine control) (-40) (248) F
2. Sensor signal (for engine control) TSWG0181
3. Sensor signal (for meter)
Breaker box inspection procedure
Characteristics of ECT sensor Perform the inspection in the following procedure if
The output voltage of ECT sensor changes according there is such an instruction to use breaker box in the
to the engine coolant temperature. The scan tool with step. After inspection, return to the diagnostic step.
CAN communication displays a constant value when
the value exceeds the threshold voltage. Therefore,
judge as it is more than the threshold value if shown as
−40°C (−40°F) or 120°C (248°F).

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
5 Short circuit to Voltage • Disconnect the 84 - Ground 0V 1V or
other signal measurement sensor more
circuit connector.
• Key switch “ON”
 Electronic control fuel injection system (Common rail type) 1E-521
On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
1E-522 Electronic control fuel injection system (Common rail type)
DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

Key switch (ON)

(15A)*

Idling Idle down Mode map Mode map Mode map

Idle up
selector switch switch 0 switch 1 switch 2
switch
switch

29 E-57 30 E-57 31 E-57 25 E-57 34 E-57 48 E-57

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

Description of circuit DTC set condition

The idling control switch is provided to adjust idle speed • When both of idling control up signal and idling
during warming-up, and is available for use when the control down signal are ON.
idling control selector switch is in “Manual”. The power
supply voltage is supplied to the idling control switch Action taken when DTC is set
through the key switch. By pressing the “Up” or “Down”, • Turns the diagnosis lamp ON.
each ground circuit is completed and the signal is input
to the ECM. Back-up mode
The ECM sets the DTC when the signal inputs are
detected for idling control switch “Up” side and “Down” • Unable to change the speed in mode driving
side at the same time.
Recovery from failure
Main trouble symptom Refer to “List of diagnostic trouble code” and “About
Operationality is not affected. recovery from failure” in this section for recovery from
failure.
Preconditions when DTC is set
• Key switch input voltage is 18V or more.
 Electronic control fuel injection system (Common rail type) 1E-523
The conditions to clear the MIL/DTC Following inspections are necessary to detect these
• The present trouble turns to history trouble when causes.
the condition is out of the range from DTC set • Improper connection of harness connector and
condition (recovery from failure). ECM connector
• Using the scan tool, or memory clear switch and – Poor connection of terminal from connector
diagnostic switch operation enables to clear DTCs. – Unmatched terminals are fitted.
– Damage of connector lock
Diagnostic aid – Poor contact between terminal and wire
If the intermittent trouble is suspected, followings may • Damaged harness
be the cause. – Visually check the harness for damage.
• Fault in switch body – Check the relevant items on the scan tool data
• Improper adjustment of switch display while moving the connector and the
• Improper connection of harness connector harness which are related to the sensor. The
• Defective harness routing variation of the display indicates the faulty part.
• Worn harness cladding
Test description
• Wire disconnection inside harness cladding
Numbers below indicate step numbers in the chart.
3. If the “Idle up switch” and “Idle down switch” display
“OFF” when the idling control switch connector is
removed, the circuit is shorted between idle up circuit
and idle down circuit, or the switch is faulty.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
2 Is the scan tool available? — Go to Step 3. Go to Step 4.
1. Turn the key switch to “OFF”.
2. Disconnect the idling control switch
connector.
3. Turn the key switch to “ON”.
3 4. Check for “Idle up switch” and “Idle down —
switch” on the data display using scan
tool.
Are the “Idle up switch” and “Idle down switch”
displayed “OFF”? Go to Step 6. Go to Step 4.
1. Check the idle up-side circuit between
idling control switch and ECM for short
circuit to the power supply circuit or
ignition power supply circuit using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.
4 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 10. Go to Step 5.
1E-524 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the idle down-side circuit between
idling control switch and ECM for short
circuit to the power supply circuit or
ignition power supply circuit using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.
5 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 10. Go to Step 7.
Replace the idling control switch.
6 —
Is the procedure completed? Go to Step 10. —
7 Is EMPS available? — Go to Step 8. Go to Step 9.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
8 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 10. Go to Step 9.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
9 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 10. —

Check if DTC is not detected again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
10 diagnosis” in this section for how to clear —
DTCs.
3. Turn the key switch to “OFF” for more than
15 seconds, and then start the engine.
4. Check the DTC.
Is the procedure completed? Go to Step 11. —
 Electronic control fuel injection system (Common rail type) 1E-525

Step Action Value YES NO

Check if other DTC is detected.
11 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.

About idling control switch Breaker box inspection procedure

Perform the inspection in the following procedure if
Note:
there is such an instruction to use breaker box in the
Refer to the machine’s manual for installing
step. After inspection, return to the diagnostic step.
position of the idling control switch.

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
4 Short circuit to Voltage • Disconnect the 30 - Ground 0V 18V or
power supply measurement switch connector. more
circuit • Key switch “ON”
5 Short circuit to Voltage • Disconnect the 31 - Ground 0V 18V or
power supply measurement switch connector. more
circuit • Key switch “ON”
1E-526 Electronic control fuel injection system (Common rail type)
DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault
4HK1

2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

Injector Injector Injector Injector

(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)

3 3
3 E-35 3 E-37 E-27 E-31

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

R L/Y L/R R W L L/W W

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

Cylinder No. 3 Cylinder No. 2 Cylinder No. 1 Cylinder No. 4

Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSHK0031
 Electronic control fuel injection system (Common rail type) 1E-527
6HK1

Injector Injector Injector Injector Injector Injector

(Cylinder No. 5) (Cylinder No. 6) (Cylinder No. 4) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 3)

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

3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

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

Feedback Feedback Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSWG0076

Description of circuit Preconditions when DTC is set

The COMMON circuit is provided to supply the power • Main relay power supply voltage is 18V or more.
supply voltage pressurized in the charge circuit inside • 70 rpm or more
the ECM to the injector, and is divided in to two systems • None of the following DTC sets are detected; DTC
(4H: 2 cylinders each, 6H: 3 cylinders each). The P0611 and P1261 and P201; DTC P0611 and
COMMON 1 circuit supplies the power supply voltage P1261 and P0202; DTC P0611 and P1261 and
to the injectors (4H: No. 1, No. 2 cylinders, 6H: No. 1, P0203.
No. 2, No. 3 cylinders). The ECM sets the DTC when
faults are detected simultaneously for all the injector DTC set condition
drive circuits of COMMON 1 system.
• None of injector monitor input signal for COMMON
Main trouble symptom 1 system exists for 3 seconds or more.

• Intense engine vibration Action taken when DTC is set

• Rough idling
• Turns the diagnosis lamp ON.
• Output lowering
• Engine blow up fault
• Engine stall possible
1E-528 Electronic control fuel injection system (Common rail type)
Back-up mode Diagnostic aid
Common 1 stop (#1, #4 cylinders stopped), EGR If the intermittent trouble is suspected, followings may
stopped (4HK1) be the cause.
Common 1 stop (#1, #2, #3 cylinders stopped), EGR • Improper connection of harness connector
stopped (6HK1) • Defective harness routing
• Worn harness cladding
Recovery from failure
• Wire disconnection inside harness cladding
Refer to “List of diagnostic trouble code” and “About Following inspections are necessary to detect these
recovery from failure” in this section for recovery from causes.
failure.
• Improper connection of harness connector and
ECM connector
The conditions to clear the MIL/DTC
– Poor connection of terminal from connector
• The present trouble turns to history trouble when
– Unmatched terminals are fitted.
the condition is out of the range from DTC set
condition (recovery from failure). – Damage of connector lock
• The diagnosis lamp will go off after the code turns – Poor contact between terminal and wire
to history trouble and the key switch is turned • Damaged harness
“OFF” then “ON” again. – Visually check the harness for damage.
• Using the scan tool, or memory clear switch and – Check the relevant items on the scan tool data
diagnostic switch operation enables to clear DTCs. display while moving the connector and the
harness which are related to the sensor. The
variation of the display indicates the faulty part.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Turn the key switch to “OFF”.
2. Remove the ECM-side harness connector
from the coupling connector (H-94).
3. Connect the DMM between the injector
power supply 1 circuit and the ground.
2 7.0V
4. Turn the key switch to “ON”.
4H: H94 female-side No. 1
6H: H94 female-side No. 3
Is the DMM indication more than the specified
value? Go to Step 3. Go to Step 4.
1. Turn the key switch to “OFF”.
2. Remove the ECM-side harness connector
from the coupling connector (H-94).
3. Measure the resistance between the
3 injector harness connector terminals. 1.0Ω
4H: H94 male-side No. 1 and No. 4
6H: H94 male-side No. 3 and No. 4
Is the resistance less than the specified value? Go to Step 6. Go to Step 22.
Check for installation condition of the injector
harness connector, ECM connector and
coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 27. Go to Step 5.
 Electronic control fuel injection system (Common rail type) 1E-529

Step Action Value YES NO

1. Check for followings in the injector power
supply 1 circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
5 —
• Open circuit
• High resistance
• Short circuit to ground
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Turn the key switch to “OFF”.
2. Remove the ECM-side harness connector
from the coupling connector (H-94).
3. Measure the resistance between the No. 1
cylinder injector drive circuit and the
6 ground. 10 MΩ
4H: H94 male-side No. 5
6H: H94 male-side No. 2
Is the resistance more than the specified
value? Go to Step 7. Go to Step 9.
1. Turn the key switch to “OFF”.
2. Remove the ECM-side harness connector
from the coupling connector (H-94).
3. Measure the resistance between the No. 2
cylinder (4H: No. 4 cylinder) injector drive
7 circuit and the ground. 10 MΩ
4H: H94 male-side No. 8
6H: H94 male-side No. 7
Is the resistance more than the specified 4H: Go to Step 12.
value? 6H: 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).
3. Measure the resistance between the No. 3
8 cylinder injector drive circuit and the 10 MΩ
ground.
6H: H94 male-side No. 6
Is the resistance more than the specified
value? Go to Step 12. Go to Step 11.
1E-530 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

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 “Breaker box inspection
procedure”.
9 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Check the No. 2 cylinder (4H: No. 4
cylinder) injector drive circuit between
ECM and coupling connector (H-94) for
ground short circuit, using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.
10 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Check the No. 3 cylinder injector drive
circuit between ECM and coupling
connector (H-94) for ground short circuit
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
11 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Remove the cylinder head cover.
2. Check for installation condition of the
injector harness.
12 3. If the trouble is detected, repair as —
required.
Is the trouble detected? Go to Step 27. Go to Step 13.
 Electronic control fuel injection system (Common rail type) 1E-531

Step Action Value YES NO

1. Remove the injector harness from the
injector.
4H: No. 1 cylinder, No. 4 cylinder
6H: No. 1 cylinder, No. 2 cylinder, No. 3
13 cylinder 10 MΩ
2. Measure the resistance between each
injector terminal and the ground.
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
14 cylinder injector drive circuit and the 0V
ground.
4H: H94 female-side No. 5
6H: H94 female-side No. 2
4. Turn the key switch to “ON”.
Is the DMM indication specified value? Go to Step 18. Go to Step 15.
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. 2
cylinder (4H: No. 4 cylinder) injector drive
15 circuit and the ground. 0V
4H: H94 female-side No. 8
6H: H94 female-side No. 7
4. Turn the key switch to “ON”.
Is the DMM indication more than the specified 4H: Go to Step 17.
value? Go to Step 19. 6H: Go to Step 16.
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. 3
16 cylinder injector drive circuit and the 0V
ground.
6H: H94 female-side No. 6
4. Turn the key switch to “ON”.
Is the DMM indication more than the specified
value? Go to Step 20. Go to Step 17.
1E-532 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

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 injector
17 power supply 1 circuit and the ground. 7.0V
4H: H94 female-side No. 1
6H: H94 female-side No. 3
4. Turn the key switch to “ON”.
Is the DMM indication less than the specified
value? Go to Step 22. Go to Step 21.
1. Check the No. 1 cylinder injector drive
circuit between ECM and coupling
connector (H-94) for short circuit to the
power supply circuit or ignition power
supply circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
18 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Check the No. 2 cylinder (4H: No. 4
cylinder) injector drive circuit between
ECM and coupling connector (H-94) for
short circuit to the power supply circuit or
ignition power supply circuit, using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.
19 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
 Electronic control fuel injection system (Common rail type) 1E-533

Step Action Value YES NO

1. Check the No. 3 cylinder injector drive
circuit between ECM and coupling
connector (H-94) for short circuit to the
power supply circuit or ignition power
supply circuit, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
20 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Check the injector power supply 1 circuit
between ECM and coupling connector (H-
94) for short circuit to the power supply
circuit or ignition power supply circuit
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
21 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
Replace the injector harness.
22 —
Is the procedure completed? Go to Step 27. —
Replace the injector.

Note:
23 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 27. —

24 Is EMPS available? — Go to Step 25. Go to Step 26.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
25 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 27. Go to Step 26.

1E-534 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
26 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 27. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
27 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1261 detected? Go to Step 2. Go to Step 28.
Check if other DTC is detected.
28 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM
 Electronic control fuel injection system (Common rail type) 1E-535

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
5 Open circuit/ Resistance • Remove the 121 - Female-side 100Ω or 10 MΩ or
high measurement ECM-side terminal less more
resistance harness (4H: No. 1, 6H: No.
connector from 3)
the coupling
connector.
• Key switch “OFF”
Short circuit to Resistance • Remove the 121 - Ground 10 MΩ or 100Ω or
ground measurement ECM-side more less
harness
connector from
the coupling
connector.
• Key switch “OFF”
9 Short circuit to Resistance • Remove the 119 - Ground 10 MΩ or 100Ω or
ground measurement ECM-side more less
harness
connector from
the coupling
connector.
• Key switch “OFF”
10 Short circuit to Resistance • Remove the 114 - Ground 10 MΩ or 100Ω or
ground measurement ECM-side more less
harness
connector from
the coupling
connector.
• Key switch “OFF”
11 Short circuit to Resistance • Remove the 117 - Ground 10 MΩ or 100Ω or
ground measurement ECM-side more less
harness
connector from
the coupling
connector.
• Key switch “OFF”
18 Short circuit to Voltage • Remove the 119 - Ground 0V 18V or
power supply measurement ECM-side more
circuit harness
connector from
the coupling
connector.
• Key switch “OFF”
19 Short circuit to Voltage • Remove the 114 - Ground 0V 18V or
power supply measurement ECM-side more
circuit harness
connector from
the coupling
connector.
• Key switch “OFF”
1E-536 Electronic control fuel injection system (Common rail type)

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
20 Short circuit to Voltage • Remove the 117 - Ground 0V 18V or
power supply measurement ECM-side more
circuit harness
connector from
the coupling
connector.
• Key switch “OFF”
21 Short circuit to Voltage • Remove the 121 - Ground 0V 18V or
power supply measurement ECM-side more
circuit harness
connector from
the coupling
connector.
• Key switch “OFF”
 Electronic control fuel injection system (Common rail type) 1E-537
DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault
4HK1

2 1 2 1 2 1 1 2
E-35 E-37 E-27 E-31

Injector Injector Injector Injector

(Cylinder No. 3) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 4)

3 3
3 E-35 3 E-37 E-27 E-31

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

3 H-94 7 H-94 6 H-94 2 H-94 1 H-94 5 H-94 8 H-94 4 H-94

1.25 0.75 0.75 1.25 1.25 0.75 0.75 1.25

R L/Y L/R R W L L/W W

3 H-12 6 H-12 7 H-12 4 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 121 E-56 119 E-56 117 E-56

Cylinder No. 3 Cylinder No. 2 Cylinder No. 1 Cylinder No. 4

Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSHK0031
1E-538 Electronic control fuel injection system (Common rail type)
6HK1

Injector Injector Injector Injector Injector Injector

(Cylinder No. 5) (Cylinder No. 6) (Cylinder No. 4) (Cylinder No. 2) (Cylinder No. 1) (Cylinder No. 3)

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

3 H-12 6 H-12 7 H-12 11 H-12 4 H-12 12 H-12 8 H-12 5 H-12

116 E-56 120 E-56 118 E-56 115 E-56 121 E-56 114 E-56 119 E-56 117 E-56

Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

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

Feedback Feedback Feedback Feedback Feedback Feedback

B+ B+

Engine control module (ECM)

TSWG0076

Description of circuit Preconditions when DTC is set

The COMMON circuit is provided to supply the power • Main relay power supply voltage is 18V or more.
supply voltage pressurized in the charge circuit inside • 70 rpm or more
the ECM to the injector, and is divided in to two systems • None of the following DTC sets are detected;
(4H: 2 cylinders each, 6H: 3 cylinders each). The P0612, P1262 and P0204; P0612, P1262 and
COMMON 2 circuit supplies the power supply voltage P0205; P0612, P1262 and P0206.
to the injectors (4H: No. 3, No. 4 cylinders, 6H: No. 4,
No. 5, No. 6 cylinders). The ECM sets the DTC when DTC set condition
faults are detected simultaneously for all the injector
drive circuits of COMMON 2 system. • None of injector monitor input signal for COMMON
2 system exists for 3 seconds or more.
Main trouble symptom
Action taken when DTC is set
• Intense engine vibration
• Turns the diagnosis lamp ON.
• Rough idling
• Output lowering
• Engine blow up fault
• Engine stall possible
 Electronic control fuel injection system (Common rail type) 1E-539
Back-up mode Diagnostic aid
Common 2 stop (#2, #3 cylinders stopped), EGR If the intermittent trouble is suspected, followings may
stopped (4HK1) be the cause.
Common 2 stop (#4, #5, #6 cylinders stopped), EGR • Improper connection of harness connector
stopped (6HK1) • Defective harness routing
• Worn harness cladding
Recovery from failure
• Wire disconnection inside harness cladding
Refer to “List of diagnostic trouble code” and “About Following inspections are necessary to detect these
recovery from failure” in this section for recovery from causes.
failure.
• Improper connection of harness connector and
ECM connector
The conditions to clear the MIL/DTC
– Poor connection of terminal from connector
• The present trouble turns to history trouble when
– Unmatched terminals are fitted.
the condition is out of the range from DTC set
condition (recovery from failure). – Damage of connector lock
• The diagnosis lamp will go off after the code turns – Poor contact between terminal and wire
to history trouble and the key switch is turned • Damaged harness
“OFF” then “ON” again. – Visually check the harness for damage.
• Using the scan tool, or memory clear switch and – Check the relevant items on the scan tool data
diagnostic switch operation enables to clear DTCs. display while moving the connector and the
harness which are related to the sensor. The
variation of the display indicates the faulty part.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Turn the key switch to “OFF”.
2. Disconnect the ECM-side harness
connector from the coupling connector
(4H: H-94, 6H: H-95).
3. Connect the DMM between the injector
2 power supply 2 circuit and the ground. 7.0V
4. Turn the key switch to “ON”.
4H: H94 female-side No. 3
6H: H95 female-side No. 3
Is the DMM indication more than the specified
value? Go to Step 3. Go to Step 4.
1. Turn the key switch to “OFF”.
2. Disconnect the ECM-side harness
connector from the coupling connector
(4H: H-94, 6H: H-95).
3 3. Measure the resistance between the 1.0Ω
injector harness connector terminals.
4H: H94 male-side No. 3 and No. 2
6H: H95 male-side No. 3 and No. 4
Is the resistance less than the specified value? Go to Step 6. Go to Step 22.
Check for installation condition of the injector
harness connector, ECM connector and
coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 27. Go to Step 5.
1E-540 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for followings in the injector power
supply 2 circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
5 —
• Open circuit
• High resistance
• Short circuit to ground
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Turn the key switch to “OFF”.
2. Disconnect the ECM-side harness
connector from the coupling connector
(4H: H-94, 6H: H-95).
3. Measure the resistance between the No. 4
6 cylinder (4H: No. 2 cylinder) injector drive 10 MΩ
circuit and the ground.
4H: H94 male-side No. 7
6H: H95 male-side No. 2
Is the resistance more than the specified
value? Go to Step 7. Go to Step 9.
1. Turn the key switch to “OFF”.
2. Disconnect the ECM-side harness
connector from the coupling connector
(4H: H-94, 6H: H-95).
3. Measure the resistance between the No. 5
7 cylinder (4H: No. 3 cylinder) injector drive 10 MΩ
circuit and the ground.
4H: H94 male-side No. 6
6H: H95 male-side No. 7
Is the resistance more than the specified 4H: Go to Step 12.
value? 6H: 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).
3. Measure the resistance between the No. 6
8 cylinder injector drive circuit and the 10 MΩ
ground.
6H: H95 male-side No. 6
Is the resistance more than the specified
value? Go to Step 12. Go to Step 11.
 Electronic control fuel injection system (Common rail type) 1E-541

Step Action Value YES NO

1. Check the No. 4 cylinder (4H: No. 2
cylinder) injector drive circuit between
ECM and coupling connector (4H: H-94,
6H: H-95) for ground short circuit using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
9 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Check the No. 5 cylinder (4H: No. 3
cylinder) injector drive circuit between
ECM and coupling connector (4H: H-94,
6H: H-95) for ground short circuit using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
10 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Check the No. 6 cylinder injector drive
circuit between ECM and coupling
connector (H-95) for ground short circuit
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
11 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Remove the cylinder head cover.
2. Check for installation condition of the
injector harness.
12 3. If the trouble is detected, repair as —
required.
Is the trouble detected? Go to Step 27. Go to Step 13.
1E-542 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Remove the injector harness from the
injector.
4H: No. 2 cylinder, No. 3 cylinder
6H: No. 4 cylinder, No. 5 cylinder, No. 6
13 cylinder 10 MΩ
2. Measure the resistance between each
injector terminal and the ground.
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
(4H: H-94, 6H: H-95).
3. Connect the DMM between the No. 4
14 cylinder (4H: No. 2 cylinder) injector drive 0V
circuit and the ground.
4H: H94 female-side No. 7
6H: H95 female-side No. 2
4. Turn the key switch to “ON”.
Is the DMM indication specified value? Go to Step 18. Go to Step 15.
1. Turn the key switch to “OFF”.
2. Remove the injector-side harness
connector from the coupling connector
(4H: H-94, 6H: H-95).
3. Connect the DMM between the No. 5
cylinder (4H: No. 3 cylinder) injector drive
15 circuit and the ground. 0V
4H: H94 female-side No. 6
6H: H95 female-side No. 7
4. Turn the key switch to “ON”.
Is the DMM indication more than the specified 4H: Go to Step 17.
value? Go to Step 19. 6H: Go to Step 16.
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. 6
16 cylinder injector drive circuit and the 0V
ground.
6H: H95 female-side No. 6
4. Turn the key switch to “ON”.
Is the DMM indication more than the specified
value? Go to Step 20. Go to Step 17.
 Electronic control fuel injection system (Common rail type) 1E-543

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Remove the injector-side harness
connector from the coupling connector
(4H: H-94, 6H: H-95).
3. Connect the DMM between the injector
17 power supply 2 circuit and the ground. 7.0V
4H: H94 female-side No. 3
6H: H95 female-side No. 3
4. Turn the key switch to “ON”.
Is the DMM indication less than the specified
value? Go to Step 22. Go to Step 21.
1. Check the No. 4 cylinder (4H: No. 2
cylinder) injector drive circuit between
ECM and coupling connector (4H: H-94,
6H: H-95) for short circuit to the power
supply circuit or ignition power supply
circuit, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
18 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Check the No. 5 cylinder (4H: No. 4
cylinder) injector drive circuit between
ECM and coupling connector (4H: H-94,
6H: H-95) for short circuit to the power
supply circuit or ignition power supply
circuit, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
19 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1E-544 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the No. 6 cylinder injector drive
circuit between ECM and coupling
connector (H-95) for short circuit to the
power supply circuit or ignition power
supply circuit, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
20 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
1. Check the injector power supply 2 circuit
between ECM and coupling connector
(4H: H-94, 6H: H-95) for short circuit to the
power supply circuit or ignition power
supply circuit, using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
21 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 27. Go to Step 24.
Replace the injector harness.
22 —
Is the procedure completed? Go to Step 27. —
Replace the injector.

Note:
23 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Go to Step 27. —

24 Is EMPS available? — Go to Step 25. Go to Step 26.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
25 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 27. Go to Step 26.

 Electronic control fuel injection system (Common rail type) 1E-545

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
26 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 27. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
27 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1262 detected? Go to Step 2. Go to Step 28.
Check if other DTC is detected.
28 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.

Breaker box inspection procedure

Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM
1E-546 Electronic control fuel injection system (Common rail type)

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
5 Open circuit/ Resistance • Remove the 116 - Female-side 100Ω or 10 MΩ or
high measurement ECM-side terminal less more
resistance harness (4H: H94 No.3, 6H:
connector from H95 No.3)
the coupling
connector.
• Key switch “OFF”
Short circuit to Resistance • Remove the 116 - Ground 10 MΩ or 100Ω or
ground measurement ECM-side more less
harness
connector from
the coupling
connector.
• Key switch “OFF”
9 Short circuit to Resistance • Remove the 115 - Ground 10 MΩ or 100Ω or
ground measurement ECM-side more less
harness
connector from
the coupling
connector.
• Key switch “OFF”
10 Short circuit to Resistance • Remove the 120 - Ground 10 MΩ or 100Ω or
ground measurement ECM-side more less
harness
connector from
the coupling
connector.
• Key switch “OFF”
11 Short circuit to Resistance • Remove the 118 - Ground 10 MΩ or 100Ω or
ground measurement ECM-side more less
harness
connector from
the coupling
connector.
• Key switch “OFF”
18 Short circuit to Voltage • Remove the 115 - Ground 0V 18V or
power supply measurement ECM-side more
circuit harness
connector from
the coupling
connector.
• Key switch “OFF”
19 Short circuit to Voltage • Remove the 120 - Ground 0V 18V or
power supply measurement ECM-side more
circuit harness
connector from
the coupling
connector.
• Key switch “OFF”
 Electronic control fuel injection system (Common rail type) 1E-547

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
20 Short circuit to Voltage • Remove the 118 - Ground 0V 18V or
power supply measurement ECM-side more
circuit harness
connector from
the coupling
connector.
• Key switch “OFF”
21 Short circuit to Voltage • Remove the 116 - Ground 0V 18V or
power supply measurement ECM-side more
circuit harness
connector from
the coupling
connector.
• Key switch “OFF”
1E-548 Electronic control fuel injection system (Common rail type)
DTC: P1271 (Flash code 24) Accelerator sensor 1-2 comparison fault

A A Engine control
module (ECM)

Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V

Vcc

37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Machine
control unit

CAN HIGH CAN LOW

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

6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor

TSHK0029

Description of circuit The ECM provides 5 V to the AP sensor through 5-V

The accelerator position (AP) sensor is installed to the power supply circuit, and grounds to the inside of the
accelerator pedal. The AP sensor is the potentiometer- ECM through ground circuit. Also, the AP sensor
type sensor, and the value of output voltage changes outputs the signal voltage to the ECM through AP
according to the accelerator opening angle. Two AP sensor signal circuit. When the accelerator opening
sensors are installed, each of which includes following angle is large, the AP sensor 1 outputs high voltage,
circuits. whereas the AP sensor 2 outputs low voltage.
The ECM sets the DTC when the difference in the
• 5-V power supply circuit
accelerator opening angle is large between which is
• Ground circuit detected based on the AP sensor 1 signal, and which is
• AP sensor signal circuit detected based on the AP sensor 2 signal.

Main trouble symptom

1 system fault: No backup
2 systems fault: Accelerator opening angle is controlled
to 0%.
 Electronic control fuel injection system (Common rail type) 1E-549
Preconditions when DTC is set • The diagnosis lamp will go off after the code turns
• Key switch input voltage is 18V or more. to history trouble and the key switch is turned
“OFF” then “ON” again.
• DTC P1630, P1631, P1271, P1277, P1278,
P1282, or P1283 is not detected. • Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
DTC set condition
Diagnostic aid
Difference in opening angle between accelerator
sensors 1 and 2 is 45% or more for 3 seconds or more. If the intermittent trouble is suspected, followings may
be the cause.
• [Accelerator sensor 1 voltage + Accelerator sensor
2 voltage] is higher than 6.4 V. • Improper connection of harness connector
• [Accelerator sensor 1 voltage + Accelerator sensor • Defective harness routing
2 voltage] is lower than 3.6 V. • Worn harness cladding
• Wire disconnection inside harness cladding
Action taken when DTC is set Following inspections are necessary to detect these
• The diagnosis lamp does not come on. causes.
• Improper connection of harness connector and
Back-up mode ECM connector
• 1 system fault...No back-up – Poor connection of terminal from connector
• 2 system fault...Accelerator opening angle is – Unmatched terminals are fitted.
controlled to 0%. – Damage of connector lock
– Poor contact between terminal and wire
Recovery from failure • Damaged harness
Refer to “List of diagnostic trouble code” and “About – Visually check the harness for damage.
recovery from failure” in this section for recovery from – Check the relevant items on the scan tool data
failure. display while moving the connector and the
harness which are related to the sensor. The
The conditions to clear the MIL/DTC variation 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 Test description
condition (recovery from failure). Numbers below indicate step numbers in the chart.
3. Measure at the harness connector-side.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Turn the key switch to “OFF” for more than
10 seconds.
2 2. Start the engine. —
3. Check the DTC.
Go to “Diagnostic
Is DTC P1271 detected? Go to Step 3. aid”.
1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Connect the DMM between the sensor
power supply terminal of the AP sensor
3 connector and the ground. 4.7V
4. Turn the key switch to “ON”.
Is the DMM indication more than the specified
value? Go to Step 5. Go to Step 6.
4 Is the scan tool available? — Go to Step 5. Go to Step 18.
1E-550 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Short between the sensor power supply
terminal of the AP sensor connector and
the signal terminal using jump cable.
5 4. Turn the key switch to “ON”. 4.7V
5. Check for “Accelerator sensor 1” on the
data display using scan tool.
Is the “Accelerator sensor 1” more than the
specified value? Go to Step 8. Go to Step 7.
1. Check for high resistance in the power
supply circuit between ECM and AP
sensor using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

6 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 16. Go to Step 11.
1. Check for high resistance in the signal
circuit between ECM and AP sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

7 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 16. Go to Step 11.
1. Check for high resistance in the ground
circuit between ECM and AP sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

8 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 16. Go to Step 11.
 Electronic control fuel injection system (Common rail type) 1E-551

Step Action Value YES NO

1. Check for high resistance in the signal
circuit between ECM and AP sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

9 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 16. Go to Step 11.
1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Check the AP sensor connector terminal
10 for intermittent trouble or poor contact. —
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 16. Go to Step 12.
1. Turn the key switch to “OFF”.
2. Remove the ECM.
3. Check the ECM terminals (41, 63, 42, 60,
64, 61) for intermittent trouble or poor
11 contact. —
4. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 16. Go to Step 13.
Replace the AP sensor.
12 —
Is the procedure completed? Go to Step 16. —
13 Is EMPS available? — Go to Step 14. Go to Step 15.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
14 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 16. Go to Step 15.

1E-552 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
15 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 16. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
16 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1271 detected? Go to Step 2. Go to Step 17.
Check if other DTC is detected.
17 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Turn the key switch to “ON”.
4. Connect the DMM between the sensor
18 4.7V
power supply terminal of the AP sensor
connector and the signal circuit.
Is the DMM indication more than the specified
value? Go to Step 8. Go to Step 7.

About AP sensor Characteristics of AP sensor

Refer to the machine’s manual for installing position of
the AP sensor.
(V)

0 99.8 (%)

TSWG0200
 Electronic control fuel injection system (Common rail type) 1E-553
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Open circuit/ Resistance • Disconnect the 42 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector sensor less more
resistance connector. power supply
• Key switch “OFF” terminal
7 Open circuit/ Resistance • Disconnect the 41 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector sensor less more
resistance connector. ground terminal
• Key switch “OFF”
8 Open circuit/ Resistance • Disconnect the 63 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector sensor less more
resistance connector. signal terminal
• Key switch “OFF”
9 Open circuit/ Resistance • Disconnect the 64 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector sensor less more
resistance connector. signal terminal
• Key switch “OFF”
1E-554 Electronic control fuel injection system (Common rail type)
DTC: P1277 (Flash code 24) Accelerator sensor 1 fault (low voltage fault)

A A Engine control
module (ECM)

Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V

Vcc

37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Machine
control unit

CAN HIGH CAN LOW

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

6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor

TSHK0029

Description of circuit Main trouble symptom

The accelerator position (AP) sensor is installed to the 1 system fault: No backup
accelerator pedal. The AP sensor is the potentiometer- 2 systems fault: Accelerator opening angle is controlled
type sensor, and the value of output voltage changes to 0%.
according to the accelerator opening angle. The AP
sensor includes following circuits. Preconditions when DTC is set
• 5-V power supply circuit • Key switch input voltage is 18V or more.
• Ground circuit • DTC P1630, P1277, or P1631 is not detected.
• AP sensor signal circuit
The ECM provides 5 V to the AP sensor through 5-V DTC set condition
power supply circuit, and grounds to the inside of the • AP sensor 1 voltage is 0.2V or less for 1 second or
ECM through ground circuit. Also, the AP sensor more.
outputs the signal voltage to the ECM through AP
sensor signal circuit. The AP sensor 1 outputs high Action taken when DTC is set
voltage when the accelerator opening angle is large.
The ECM sets the DTC when the signal voltage from • The diagnosis lamp does not come on.
the AP sensor 1 is less than the normal range.
 Electronic control fuel injection system (Common rail type) 1E-555
Back-up mode • Defective harness routing
• 1 system fault...No back-up • Worn harness cladding
• 2 system fault...Accelerator opening angle is • Wire disconnection inside harness cladding
controlled to 0%. Following inspections are necessary to detect these
causes.
Recovery from failure • Improper connection of harness connector and
Refer to “List of diagnostic trouble code” and “About ECM connector
recovery from failure” in this section for recovery from – Poor connection of terminal from connector
failure. – Unmatched terminals are fitted.
– Damage of connector lock
The conditions to clear the MIL/DTC – Poor contact between terminal and wire
• The present trouble turns to history trouble when • Damaged harness
the condition is out of the range from DTC set – Visually check the harness for damage.
condition (recovery from failure).
– Check the relevant items on the scan tool data
• The diagnosis lamp will go off after the code turns display while moving the connector and the
to history trouble and the key switch is turned harness which are related to the sensor. The
“OFF” then “ON” again. variation of the display indicates the faulty part.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs. Test description
Numbers below indicate step numbers in the chart.
Diagnostic aid
3. In the case of present trouble, the “Accelerator
When the DTC P1282 is detected at the same time, the sensor 1” displays less than the specified value. If more
accelerator pedal position sensor and the accelerator than the specified value, identify the cause by referring
pedal position sensor signal circuit (before the to “Diagnostic aid”.
bifurcation point) may be faulty. 5. If the “Accelerator sensor 1” displays more than the
If the intermittent trouble is suspected, followings may specified value when terminals between the AP sensor
be the cause. connector are shorted, the circuit beyond the sensor is
• Improper connection of harness connector normal including ECM.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
2 Is the scan tool available? — Go to Step 3. Go to Step 14.
1. Turn the key switch to “ON”.
2. Check for “Accelerator sensor 1” on the
3 data display using scan tool. 0.2V
Is the “Accelerator sensor 1” less than the Go to “Diagnostic
specified value? Go to Step 4. aid”.
Check for installation condition of the AP
sensor connector, ECM connector and
coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 5.
1E-556 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Short between the sensor power supply
terminal of the AP sensor connector and
the sensor 1 signal terminal using jump
5 cable. 4.8V
4. Turn the key switch to “ON”.
5. Check for “Accelerator sensor 1” on the
data display using scan tool.
Is the “Accelerator sensor 1” more than the
specified value? Go to Step 8. Go to Step 6.
1. Check for followings in the power supply
circuit between ECM and AP sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and AP sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 —
• Short circuit to AP sensor ground circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the AP sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
 Electronic control fuel injection system (Common rail type) 1E-557

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

10 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. Go to Step 11.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
12 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1277 detected? Go to Step 2. Go to Step 13.
Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Turn the key switch to “ON”.
2. Check for “Accelerator sensor 1” on the
14 data display. 0.2V
Is the “Accelerator sensor 1” less than the Go to “Diagnostic
specified value? Go to Step 15. aid”.
Check for installation condition of the AP
sensor connector, ECM connector and
coupling connector.
1. Check for play or looseness in the
15 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 16.
1E-558 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Short between the sensor power supply
terminal of the AP sensor connector and
the sensor 1 signal terminal using jump
16 cable. 4.8V
4. Turn the key switch to “ON”.
5. Check for “Accelerator sensor 1” on the
data display.
Is the “Accelerator sensor 1” more than the
specified value? Go to Step 8. Go to Step 6.

About AP sensor Breaker box inspection procedure

Refer to the machine’s manual for installing position of Perform the inspection in the following procedure if
the AP sensor. there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Characteristics of AP sensor

(V)

0 99.8 (%)

TSWG0200
Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Open circuit/ Resistance • Disconnect the 42 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector sensor 1 less more
resistance connector. power supply
• Key switch “OFF” terminal
7 Short circuit to Resistance • Disconnect the 63 - 41 10 MΩ or 100Ω or
ground circuit/ measurement sensor 63 - Ground more less
ground connector.
• Key switch “OFF”
Open circuit/ Resistance • Disconnect the 63 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector sensor 1 less more
resistance connector. signal terminal
• Key switch “OFF”
 Electronic control fuel injection system (Common rail type) 1E-559
DTC: P1278 (Flash code 24) Accelerator sensor 1 fault (high voltage fault)

A A Engine control
module (ECM)

Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V

Vcc

37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Machine
control unit

CAN HIGH CAN LOW

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

6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor

TSHK0029

Description of circuit Main trouble symptom

The accelerator position (AP) sensor is installed to the 1 system fault: No backup
accelerator pedal. The AP sensor is the potentiometer- 2 systems fault: Accelerator opening angle is controlled
type sensor, and the value of output voltage changes to 0%.
according to the accelerator opening angle. The AP
sensor includes following circuits. Preconditions when DTC is set
• 5-V power supply circuit • Key switch input voltage is 18V or more.
• Ground circuit • DTC P1630, P1278, or P1631 is not detected.
• AP sensor signal circuit
The ECM provides 5 V to the AP sensor through 5-V DTC set condition
power supply circuit, and grounds to the inside of the • AP sensor 1 voltage is 4.9V or more for 1 second
ECM through ground circuit. Also, the AP sensor or more.
outputs the signal voltage to the ECM through AP
sensor signal circuit. The AP sensor 1 outputs high Action taken when DTC is set
voltage when the accelerator opening angle is large.
The ECM sets the DTC when the signal voltage from • The diagnosis lamp does not come on.
the AP sensor 1 is more than the normal range.
1E-560 Electronic control fuel injection system (Common rail type)
Back-up mode • Defective harness routing
• 1 system fault...No back-up • Worn harness cladding
• 2 system fault...Accelerator opening angle is • Wire disconnection inside harness cladding
controlled to 0%. Following inspections are necessary to detect these
causes.
Recovery from failure • Improper connection of harness connector and
Refer to “List of diagnostic trouble code” and “About ECM connector
recovery from failure” in this section for recovery from – Poor connection of terminal from connector
failure. – Unmatched terminals are fitted.
– Damage of connector lock
The conditions to clear the MIL/DTC – Poor contact between terminal and wire
• The present trouble turns to history trouble when • Damaged harness
the condition is out of the range from DTC set – Visually check the harness for damage.
condition (recovery from failure).
– Check the relevant items on the scan tool data
• The diagnosis lamp will go off after the code turns display while moving the connector and the
to history trouble and the key switch is turned harness which are related to the sensor. The
“OFF” then “ON” again. variation of the display indicates the faulty part.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs. Test description
Numbers below indicate step numbers in the chart.
Diagnostic aid
3. In the case of present trouble, the “Accelerator
When the DTC P1283 is detected at the same time, the sensor 1” displays more than the specified value. If less
accelerator pedal position sensor and accelerator pedal than the specified value, identify the cause by referring
position sensor signal circuit (before the bifurcation to “Diagnostic aid”.
point) may be faulty. 5. If the “Accelerator sensor 1” displays less than the
If the intermittent trouble is suspected, followings may specified value when the AP sensor connector is
be the cause. removed, the circuit beyond the sensor is normal
• Improper connection of harness connector including ECM.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
2 Is the scan tool available? — Go to Step 3. Go to Step 14.
1. Turn the key switch to “ON”.
2. Check for “Accelerator sensor 1” on the
3 data display using scan tool. 4.9V
Is the “Accelerator sensor 1” more than the Go to “Diagnostic
specified value? Go to Step 4. aid”.
Check for installation condition of the AP
sensor connector, ECM connector and
coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 5.
1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Turn the key switch to “ON”.
5 4. Check for “Accelerator sensor 1” on the 0.1V
data display using scan tool.
Is the “Accelerator sensor 1” less than the
specified value? Go to Step 8. Go to Step 6.
 Electronic control fuel injection system (Common rail type) 1E-561

Step Action Value YES NO

1. Check the signal circuit between ECM and
AP sensor 1 for short circuit to the power
supply circuit or ignition power supply
circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —

Important:
If the AP sensor circuit is shorted to the power
supply circuit, the sensor may be broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the ground circuit
between ECM and AP sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the AP sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. Go to Step 11.

1E-562 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
12 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1278 detected? Go to Step 2. Go to Step 13.
Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Turn the key switch to “ON”.
2. Check for “Accelerator sensor 1” on the
14 data display. 4.9V
Is the “Accelerator sensor 1” more than the Go to “Diagnostic
specified value? Go to Step 15. aid”.
Check for installation condition of the AP
sensor connector, ECM connector and
coupling connector.
1. Check for play or looseness in the
15 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 16.
1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Turn the key switch to “ON”.
16 4. Check for “Accelerator sensor 1” on the 0.1V
data display.
Is the “Accelerator sensor 1” less than the
specified value? Go to Step 8. Go to Step 6.

About AP sensor
Refer to the machine’s manual for installing position of
the AP sensor.
 Electronic control fuel injection system (Common rail type) 1E-563
Characteristics of AP sensor Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
(V) step. After inspection, return to the diagnostic step.

0 99.8 (%)

TSWG0200

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Voltage • Disconnect the 63 - Ground 0V 18V or
power supply measurement sensor more
circuit connector.
• Key switch “ON”
7 Open circuit/ Resistance • Disconnect the 41 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector sensor 1 less more
resistance connector. ground terminal
• Key switch “OFF”
1E-564 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)

Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V

Vcc

37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Machine
control unit

CAN HIGH CAN LOW

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

6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor

TSHK0029

Description of circuit Main trouble symptom

The accelerator position (AP) sensor is installed to the 1 system fault: No backup
accelerator pedal. The AP sensor is the potentiometer- 2 systems fault: Accelerator opening angle is controlled
type sensor, and the value of output voltage changes to 0%.
according to the accelerator opening angle. The AP
sensor includes following circuits. Preconditions when DTC is set
• 5-V power supply circuit • Key switch input voltage is 18V or more.
• Ground circuit • DTC P1630, P1282, P1631 is not detected.
• AP sensor signal circuit
The ECM provides 5 V to the AP sensor through 5-V DTC set condition
power supply circuit, and grounds to the inside of the • AP sensor 2 voltage is 0.2V or less for 1 second or
ECM through ground circuit. Also, the AP sensor more.
outputs the signal voltage to the ECM through AP
sensor signal circuit. The AP sensor 1 outputs high Action taken when DTC is set
voltage when the accelerator opening angle is large.
The ECM sets the DTC when the signal voltage from • The diagnosis lamp does not come on.
the AP sensor 2 is less than the normal range.
 Electronic control fuel injection system (Common rail type) 1E-565
Back-up mode • Defective harness routing
• 1 system fault...No back-up • Worn harness cladding
• 2 system fault...Accelerator opening angle is • Wire disconnection inside harness cladding
controlled to 0%. Following inspections are necessary to detect these
causes.
Recovery from failure • Improper connection of harness connector and
Refer to “List of diagnostic trouble code” and “About ECM connector
recovery from failure” in this section for recovery from – Poor connection of terminal from connector
failure. – Unmatched terminals are fitted.
– Damage of connector lock
The conditions to clear the MIL/DTC – Poor contact between terminal and wire
• The present trouble turns to history trouble when • Damaged harness
the condition is out of the range from DTC set – Visually check the harness for damage.
condition (recovery from failure).
– Check the relevant items on the scan tool data
• The diagnosis lamp will go off after the code turns display while moving the connector and the
to history trouble and the key switch is turned harness which are related to the sensor. The
“OFF” then “ON” again. variation of the display indicates the faulty part.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs. Test description
Numbers below indicate step numbers in the chart.
Diagnostic aid
3. In the case of present trouble, the “Accelerator
When the DTC P1277 is detected at the same time, the sensor 2” displays less than the specified value. If more
accelerator pedal position sensor and accelerator pedal than the specified value, identify the cause by referring
position sensor signal circuit (before the bifurcation to “Diagnostic aid”.
point) may be faulty. 5. If the “Accelerator sensor 2” displays more than the
If the intermittent trouble is suspected, followings may specified value when terminals between the AP sensor
be the cause. connector are shorted, the circuit beyond the sensor is
• Improper connection of harness connector normal including ECM.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
2 Is the scan tool available? — Go to Step 3. Go to Step 14.
1. Turn the key switch to “ON”.
2. Check for “Accelerator sensor 2” on the
3 data display using scan tool. 0.2V
Is the “Accelerator sensor 2” less than the Go to “Diagnostic
specified value? Go to Step 4. aid”.
Check for installation condition of the AP
sensor connector, ECM connector and
coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 5.
1E-566 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Short between the sensor power supply
terminal of the AP sensor connector and
the sensor 2 signal terminal using jump
5 cable. 4.8V
4. Turn the key switch to “ON”.
5. Check for “Accelerator sensor 2” on the
data display using scan tool.
Is the “Accelerator sensor 2” more than the
specified value? Go to Step 8. Go to Step 6.
1. Check for followings in the power supply
circuit between ECM and AP sensor 1
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the signal circuit
between ECM and AP sensor 1 using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.
7 —
• Short circuit to AP sensor 1 ground
circuit
• Short circuit to ground
• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the AP sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
 Electronic control fuel injection system (Common rail type) 1E-567

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

10 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. Go to Step 11.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
12 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1282 detected? Go to Step 2. Go to Step 13.
Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Turn the key switch to “ON”.
2. Check for “Accelerator sensor 2” on the
14 data display. 0.2V
Is the “Accelerator sensor 2” less than the Go to “Diagnostic
specified value? Go to Step 15. aid”.
Check for installation condition of the AP
sensor connector, ECM connector and
coupling connector.
1. Check for play or looseness in the
15 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 16.
1E-568 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Short between the sensor power supply
terminal of the AP sensor connector and
the sensor 2 signal terminal using jump
16 cable. 4.8V
4. Turn the key switch to “ON”.
5. Check for “Accelerator sensor 2” on the
data display.
Is the “Accelerator sensor 2” more than the
specified value? Go to Step 8. Go to Step 6.

About AP sensor Breaker box inspection procedure

Refer to the machine’s manual for installing position of Perform the inspection in the following procedure if
the AP sensor. there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.
Characteristics of AP sensor

(V)

0 99.8 (%)

TSWG0200
Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Open circuit/ Resistance • Disconnect the 61 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector sensor 1 less more
resistance connector. power supply
• Key switch “OFF” terminal
7 Short circuit to Resistance • Disconnect the 64 - 61 10 MΩ or 100Ω or
ground circuit/ measurement sensor 64 - Ground more less
ground connector.
• Key switch “OFF”
Open circuit/ Resistance • Disconnect the 64 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector sensor 1 less more
resistance connector. signal terminal
• Key switch “OFF”
 Electronic control fuel injection system (Common rail type) 1E-569
DTC: P1283 (Flash code 24) Accelerator sensor 2 fault (high voltage fault)

A A Engine control
module (ECM)

Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V

Vcc

37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Machine
control unit

CAN HIGH CAN LOW

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

6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor

TSHK0029

Description of circuit Main trouble symptom

The accelerator position (AP) sensor is installed to the 1 system fault: No backup
accelerator pedal. The AP sensor is the potentiometer- 2 systems fault: Accelerator opening angle is controlled
type sensor, and the value of output voltage changes to 0%.
according to the accelerator opening angle. The AP
sensor includes following circuits. Preconditions when DTC is set
• 5-V power supply circuit • Key switch input voltage is 18V or more.
• Ground circuit • DTC P1630, P1283, or P1631 is not detected.
• AP sensor signal circuit
The ECM provides 5 V to the AP sensor through 5-V DTC set condition
power supply circuit, and grounds to the inside of the • AP sensor 2 voltage is 4.9V or more for 1 second
ECM through ground circuit. Also, the AP sensor or more.
outputs the signal voltage to the ECM through AP
sensor signal circuit. The AP sensor 1 outputs high Action taken when DTC is set
voltage when the accelerator opening angle is large.
The ECM sets the DTC when the signal voltage from • The diagnosis lamp does not come on.
the AP sensor 2 is more than the normal range.
1E-570 Electronic control fuel injection system (Common rail type)
Back-up mode • Defective harness routing
• 1 system fault...No back-up • Worn harness cladding
• 2 system fault...Accelerator opening angle is • Wire disconnection inside harness cladding
controlled to 0%. Following inspections are necessary to detect these
causes.
Recovery from failure • Improper connection of harness connector and
Refer to “List of diagnostic trouble code” and “About ECM connector
recovery from failure” in this section for recovery from – Poor connection of terminal from connector
failure. – Unmatched terminals are fitted.
– Damage of connector lock
The conditions to clear the MIL/DTC – Poor contact between terminal and wire
• The present trouble turns to history trouble when • Damaged harness
the condition is out of the range from DTC set – Visually check the harness for damage.
condition (recovery from failure).
– Check the relevant items on the scan tool data
• The diagnosis lamp will go off after the code turns display while moving the connector and the
to history trouble and the key switch is turned harness which are related to the sensor. The
“OFF” then “ON” again. variation of the display indicates the faulty part.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs. Test description
Numbers below indicate step numbers in the chart.
Diagnostic aid
3. In the case of present trouble, the “Accelerator
When the DTC P1278 is detected at the same time, the sensor 2” displays more than the specified value. If less
accelerator pedal position sensor and accelerator pedal than the specified value, identify the cause by referring
position sensor signal circuit (before the bifurcation to “Diagnostic aid”.
point) may be faulty. 5. If the “Accelerator sensor 2” displays less than the
If the intermittent trouble is suspected, followings may specified value when the AP sensor connector is
be the cause. removed, the circuit beyond the sensor is normal
• Improper connection of harness connector including ECM.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
2 Is the scan tool available? — Go to Step 3. Go to Step 14.
1. Turn the key switch to “ON”.
2. Check for “Accelerator sensor 2” on the
3 data display using scan tool. 4.9V
Is the “Accelerator sensor 2” more than the Go to “Diagnostic
specified value? Go to Step 4. aid”.
Check for installation condition of the AP
sensor connector, ECM connector and
coupling connector.
1. Check for play or looseness in the
4 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 5.
1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Turn the key switch to “ON”.
5 4. Check for “Accelerator sensor 2” on the 0.1V
data display using scan tool.
Is the “Accelerator sensor 2” less than the
specified value? Go to Step 8. Go to Step 6.
 Electronic control fuel injection system (Common rail type) 1E-571

Step Action Value YES NO

1. Check the signal circuit between ECM and
AP sensor 1 for short circuit to the power
supply circuit or ignition power supply
circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
6 board check procedure for sensors”. —

Important:
If the AP sensor circuit is shorted to the power
supply circuit, the sensor may be broken.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 12. Go to Step 7.
1. Check for followings in the ground circuit
between ECM and AP sensor using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
7 —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 9.
Replace the AP sensor.
8 —
Is the procedure completed? Go to Step 12. —
9 Is EMPS available? — Go to Step 10. Go to Step 11.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
10 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. Go to Step 11.

1E-572 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
11 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 12. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
12 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1283 detected? Go to Step 2. Go to Step 13.
Check if other DTC is detected.
13 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Turn the key switch to “ON”.
2. Check for “Accelerator sensor 2” on the
14 data display. 4.9V
Is the “Accelerator sensor 2” more than the Go to “Diagnostic
specified value? Go to Step 15. aid”.
Check for installation condition of the AP
sensor connector, ECM connector and
coupling connector.
1. Check for play or looseness in the
15 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 12. Go to Step 16.
1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Turn the key switch to “ON”.
16 4. Check for “Accelerator sensor 2” on the 0.1V
data display.
Is the “Accelerator sensor 2” less than the
specified value? Go to Step 8. Go to Step 6.

About AP sensor
Refer to the machine’s manual for installing position of
the AP sensor.
 Electronic control fuel injection system (Common rail type) 1E-573
Characteristics of AP sensor Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
(V) step. After inspection, return to the diagnostic step.

0 99.8 (%)

TSWG0200

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Voltage • Disconnect the 64 - Ground 0V 18V or
power supply measurement sensor more
circuit connector.
• Key switch “ON”
7 Open circuit/ Resistance • Disconnect the 60 - Sensor 100Ω or 10 MΩ or
high measurement sensor connector sensor 1 less more
resistance connector. ground terminal
• Key switch “OFF”
1E-574 Electronic control fuel injection system (Common rail type)
DTC: P1345 (Flash code 16) Cam sensor out of phase

Engine control
module(ECM)
CMP sensor Common rail pressure
signal sensor signal
5V

CKP CKP
HIGH LOW
signal signal

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 108 E-56 107 E-56 106 E-56

4 H-20 5 H-20 6 H-20 14 H-20 13 H-20 12 H-20 3 H-20 2 H-20 1 H-20

0.75 Br

0.75 0.75 0.75

0.75 0.75
W/R B/W Br
B/R W/L

2 E-98 1 E-98
0.75 0.75 0.75 0.75
Br B G W

CKP sensor
1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113

CMP sensor Common rail pressure sensor

TSHK0033

Description of circuit Preconditions when DTC is set

The crankshaft position (CKP) sensor generates pulse • Key switch input voltage is 18V or more.
when the tooth of the flywheel passes the sensor. Also, • DTC P0335, P0336, P0340, P0341, P1345, or
the camshaft position (CMP) sensor, the same as CKP P1635 is not detected.
sensor, generates pulse when the sensing hole for • Cam pulse is normal.
signal detection installed in the supply pump camshaft
• Crank pulse is normal.
gear passes the sensor.
The ECM sets the DTC when the number of pulses for
DTC set condition
CKP sensor and CMP sensor are normal but mutual
pulses do not synchronize. • Correct CMP sensor pulse does not exist in crank
gap position.
Main trouble symptom
Action taken when DTC is set
• Behavior does not change during engine running.
• After engine stops, engine will not start. • Turns the diagnosis lamp ON.

Back-up mode
Specified back-up value (depending on the machine
manufacturer)
 Electronic control fuel injection system (Common rail type) 1E-575
Recovery from failure • Defective harness routing
Refer to “List of diagnostic trouble code” and “About • Worn harness cladding
recovery from failure” in this section for recovery from • Wire disconnection inside harness cladding
failure. • Excessive air mixed in the fuel.
Following inspections are necessary to detect these
The conditions to clear the MIL/DTC causes.
• The present trouble turns to history trouble when • Improper connection of harness connector and
the condition is out of the range from DTC set ECM connector
condition (recovery from failure). – Poor connection of terminal from connector
• The diagnosis lamp will go off after the code turns – Unmatched terminals are fitted.
to history trouble and the key switch is turned – Damage of connector lock
“OFF” then “ON” again.
– Poor contact between terminal and wire
• Using the scan tool, or memory clear switch and
• Damaged harness
diagnostic switch operation enables to clear DTCs.
– Visually check the harness for damage.
Diagnostic aid – Check the relevant items on the scan tool data
display while moving the connector and the
If the intermittent trouble is suspected, followings may
harness which are related to the sensor. The
be the cause.
variation of the display indicates the faulty part.
• Improper connection of harness connector

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Check the CMP sensor condition.
• Improper connection of harness
connector
2 • Loose installation and rattling of sensor —
2. If the trouble is detected, repair as
required.
Is the procedure completed? Go to Step 3. —
1. Check for the condition of the CKP sensor.
• Improper connection of harness
connector
3 • Loose installation and rattling of sensor —
2. If the trouble is detected, repair as
required.
Is the procedure completed? Go to Step 4. —
1E-576 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2. Turn the key switch to “OFF” for more than
10 seconds.
3. Test run with the “Preconditions when
DTC is set”.
4 4. Check the DTC. —
• Stop the engine once, crank the engine
for 4 to 5 seconds, and then check if
P0340 is detected.
• If DTC P0340 is detected, judge as an
open circuit in cam sensor, and check
and repair the open circuit in cam
sensor. After repair, crank the engine
for 10 seconds, and confirm that P0340
and P1345 disappear.
Is DTC P1345 detected? Go to Step 5. —
1. Check that the camshaft gear is installed
properly.
5 2. If the trouble is detected, repair as —
required.
Is the procedure completed? Go to Step 6. —
1. Check that the flywheel is installed
properly.
6 2. If the trouble is detected, repair as —
required.
Is the procedure completed? Go to Step 7. —
Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
7 2. Turn the key switch to “OFF” for more than —
15 seconds.
3. Test run with the “Preconditions when
DTC is set”.
4. Check the DTC.
Is DTC P1345 detected? Go to Step 2. Go to Step 8.
Check if other DTC is detected.
8 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-577
About CKP sensor 6HK1

TSWG0064 TSHK0129

Name About CMP sensor

1. GND
2. Power supply

4HK1

Name
1. Signal
TSHK0128 2. GND
3. Power supply
1E-578 Electronic control fuel injection system (Common rail type)
4HK1 About CKP sensor and CMP sensor signals
4HK1

15

1
1

TSHK0040

6HK1 TSHK0042

6HK1

15

1
1

TSWG0152

Name TSWG0151

1. CMP sensor Name

1. CKP signal
2. CMP signal
 Electronic control fuel injection system (Common rail type) 1E-579
DTC: P1625 (Flash code 416) Main relay fault
(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine manual.)

(MAIN)* (30A)*

Battery Main relay

5 E-57 2 E-57 40 E-57 21 E-57

B+ B+

Engine control
module (ECM)

TSWG0071

Description of circuit • 3 seconds or more has elapsed after key switch

The main relay is installed near the blower motor inside ON.
the instrument panel. The ECM turns the main relay • Main relay drive indication ON
“ON” when the key switch inputs “ON” signal, and turns • DTC P1625, or P0606 is not detected.
the main relay “OFF” when the key switch is “OFF”. The
battery voltage is supplied to the main relay via fuse, DTC set condition
and turning the main relay “ON” will supply the power • Main relay input power supply voltage is 1 V or less
supply voltage to the ECM. for 2 seconds or more.
The ECM sets the DTC when the output to/input from
• Relay does not cut off for 5 seconds or more even
the main relay do not match.
after the main relay coil OFF command is sent.
Main trouble symptom
Action taken when DTC is set
Engine does not start or power supply cannot be shut
• Turns the diagnosis lamp ON.
off.
Back-up mode
Preconditions when DTC is set
• Back-up: No back-up action
• Key switch input voltage is 18V or more.
• DTC P1630 is not detected.
1E-580 Electronic control fuel injection system (Common rail type)
Recovery from failure Following inspections are necessary to detect these
Refer to “List of diagnostic trouble code” and “About causes.
recovery from failure” in this section for recovery from • Improper connection of harness connector and
failure. ECM connector
– Poor connection of terminal from connector
The conditions to clear the MIL/DTC – Unmatched terminals are fitted.
• The present trouble turns to history trouble when – Damage of connector lock
the condition is out of the range from DTC set – Poor contact between terminal and wire
condition (recovery from failure). • Damaged harness
• The diagnosis lamp will go off after the code turns – Visually check the harness for damage.
to history trouble and the key switch is turned
– Check the relevant items on the scan tool data
“OFF” then “ON” again.
display while moving the connector and the
• Using the scan tool, or memory clear switch and harness which are related to the sensor. The
diagnostic switch operation enables to clear DTCs. variation of the display indicates the faulty part.

Diagnostic aid Test description

If the intermittent trouble is suspected, followings may Numbers below indicate step numbers in the chart.
be the cause. 4. If the main relay is stuck closed, it is possible to
• Fault in switch body communicate with ECM using scan tool even with the
• Improper adjustment of switch key switch “OFF”.
• Improper connection of harness connector 5. If it is still possible to communicate with ECM using
• Defective harness routing scan tool and the DTC is detected when the main relay
is removed, the circuit beyond the relay or ECM is
• Worn harness cladding
faulty.
• Wire disconnection inside harness cladding 8. If the “Main relay voltage” displays more than the
specified value when terminals between the main relay
installing portion are shorted, the circuit beyond the
relay is normal including ECM.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Is the scan tool (KW communication)
2 —
available? Go to Step 3. Go to Step 17.
1. Turn the key switch to “ON”.
2. Check for “Main relay voltage” on the data
3 display using scan tool. 1V
Is the “Main relay voltage” more than the
specified value? Go to Step 4. Go to Step 7.
1. Turn the key switch to “OFF”.
4 2. Check the DTC. — Go to “Diagnostic
Is DTC P1625 detected? Go to Step 5. aid”.
1. Remove the main relay.
2. Check the DTC.

Note:
5 Refer to the machine’s manual for installing —
position and installation/removal
procedures of the main relay.

Is DTC P1625 detected? Go to Step 6. Go to Step 11.

 Electronic control fuel injection system (Common rail type) 1E-581

Step Action Value YES NO

1. Check the circuit (contact point side)
between main relay and ECM for short
circuit to the power supply circuit or
ignition power supply circuit using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.
6 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 12. Go to Step 15.
Check for installation condition of the main
relay, ECM connector and coupling connector.
1. Check for play or looseness in the
7 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 15. Go to Step 8.
1. Turn the key switch to “OFF”.
2. Remove the main relay.
3. Short between the terminals 1 - 2 and 3 - 5
in the main relay installing portion
respectively using jump cable.
8 4. Turn the key switch to “ON”. 24V
5. Check for “Main relay voltage” on the data
display using scan tool.
Is the “Main relay voltage” more than the
specified value? Go to Step 11. Go to Step 9.
1. Check for following in the circuit between
slow-blow fuse and main relay.
• Open circuit
• Short circuit to ground circuit
9 • High resistance —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 15. Go to Step 10.
1E-582 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for followings in the circuit between
main relay and ECM using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
10 board check procedure for sensors”. —

• Open circuit
• Short circuit to ground circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 15. Go to Step 12.
Replace the main relay.
11 —
Is the procedure completed? Go to Step 15. —
12 Is EMPS available? — Go to Step 13. Go to Step 14.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
13 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 15. Go to Step 14.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
14 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 15. —

 Electronic control fuel injection system (Common rail type) 1E-583

Step Action Value YES NO

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
15 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1625 detected? Go to Step 2. Go to Step 15.
Check if other DTC is detected.
16 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1. Turn the key switch to “OFF”.
2. Remove the main relay.
3. Turn the key switch to “ON”.
4. Connect the DMM between the main relay
17 1V
connector coil-side terminal and the
ground.
Is the DMM indication more than the specified
value? Go to Step 18. Go to Step 21.
1. Turn the key switch to “OFF”.
18 2. Check the DTC. — Go to “Diagnostic
Is DTC P1625 detected? Go to Step 19. aid”.
1. Remove the main relay.
2. Check the DTC.

Note:
19 Refer to the machine’s manual for installing —
position and installation/removal
procedures of the main relay.

Is DTC P1625 detected? Go to Step 20. Go to Step 11.

1. Check the circuit (contact point side)
between main relay and ECM for short
circuit to the power supply circuit or
ignition power supply circuit using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.
20 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 12. Go to Step 15.
1E-584 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check for installation condition of the main
relay, ECM connector and coupling connector.
1. Check for play or looseness in the
21 connection. —
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 15. Go to Step 22.
1. Turn the key switch to “OFF”.
2. Remove the main relay.
3. Turn the key switch to “ON”.
22 4. Connect the DMM between the main relay 24V
connector terminal (contact point side) and
the ground.
Go to Step 11. Go to Step 9.

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
 Electronic control fuel injection system (Common rail type) 1E-585

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
6 Short circuit to Voltage • Disconnect the 2 - Ground 0V 18V or
power supply measurement relay. 5 - Ground more
circuit • Key switch “ON”
10 Open circuit/ Resistance • Disconnect the 2 - Relay installing 100Ω or 10 MΩ or
high measurement relay. terminal No. 2 less more
resistance • Key switch “OFF” 5 - Relay installing
terminal No. 2
21 - Relay installing
terminal No. 5
40 - Relay installing
terminal No. 5
Short circuit to Resistance • Disconnect the 2 - Ground 10 MΩ or 100Ω or
ground measurement relay. 5 - Ground more less
• Key switch “OFF” 21 - Ground
40 - Ground

On-board check procedure for sensors

2 1

TSWG0197

Name
1. Coupling connector between engine — the
machine
2. Machine harness
3. Sensor connector
4. Engine harness

1. Disconnect the coupling connector, and check the

sensor from engine harness connector.
2. Disconnect the connector from sensor, and short
the wiring of sensor connector.
3. Check the harness from coupling connector for
open circuit.
• If both steps 1 and 2 are faulty, repair the
harness. Check from step 1 again.
• If only step 1 is faulty, replace the sensor.
1E-586 Electronic control fuel injection system (Common rail type)
DTC: P1630 (Flash code 36) A/D conversion fault

Description of circuit Back-up mode

The ECM processes the analog signals (voltage signal • Analog sensor system default processing
etc.) which are input from each sensor into digital • Limited injection amount 3 (multi-injection stopped)
signals, to perform various controls and calculations. • Target RP upper limit (80 MPa {11603 psi})
The ECM sets the DTC when the fault is detected for
the analog-digital conversion. Recovery from failure

Main trouble symptom Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
• Output lowering failure.
• Black smoke emitted
The conditions to clear the MIL/DTC
DTC set condition
• The present trouble turns to history trouble when
• Analog/digital conversion failure the condition is out of the range from DTC set
condition (recovery from failure).
Action taken when DTC is set • The diagnosis lamp will go off after the code turns
• Turns the diagnosis lamp ON. to history trouble and the key switch is turned
“OFF” then “ON” again.
• Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check the DTC again.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2 2. Turn the key switch to “OFF” for more than —
10 seconds.
3. Test run with the “Preconditions when
DTC is set”.
4. Check the DTC.
Go to “Diagnostic
Is DTC P1630 detected? Go to Step 3. aid”.
3 Is EMPS available? — Go to Step 4. Go to Step 5.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
4 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 6. Go to Step 5.

 Electronic control fuel injection system (Common rail type) 1E-587

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
5 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 6. —

Check if other DTC is detected.
6 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1E-588 Electronic control fuel injection system (Common rail type)
DTC: P1631 (Flash code 55) Voltage fault in 5-V power supply 1

A A Engine control
module (ECM)

Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V

Vcc

37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Machine
control unit

CAN HIGH CAN LOW

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

6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor

TSHK0029

Description of circuit DTC set condition

The 5-V power supply circuit is provided to the ECM for • Key switch power supply voltage is 5.5 V or more,
5 systems. The 5-V power supply circuit 1 supplies or 4.5 V or less for 0.5 seconds or more.
power to the accelerator position (AP) sensor.
The ECM sets the DTC when the voltage in the 5-V Action taken when DTC is set
power supply circuit 1 is higher or lower than the normal • Turns the diagnosis lamp ON.
range.
Back-up mode
Main trouble symptom
• Same to accelerator sensor fault
Accelerator opening angle is controlled to 0%.
Recovery from failure
Preconditions when DTC is set
Refer to “List of diagnostic trouble code” and “About
• DTC P1630 is not detected. recovery from failure” in this section for recovery from
• Key switch input power supply voltage is higher failure.
than 16 V but lower than 32 V.
 Electronic control fuel injection system (Common rail type) 1E-589
The conditions to clear the MIL/DTC • Using the scan tool, or memory clear switch and
• The present trouble turns to history trouble when diagnostic switch operation enables to clear DTCs.
the condition is out of the range from DTC set
condition (recovery from failure). Test description
• The diagnosis lamp will go off after the code turns Numbers below indicate step numbers in the chart.
to history trouble and the key switch is turned 2. Measure at the harness connector-side.
“OFF” then “ON” again. 3. Measure at the harness connector-side.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Connect the DMM between the AP sensor
2 power supply terminal and the ground. 5.5V
4. Turn the key switch to “ON”.
Is the DMM indication more than the specified
value? Go to Step 4. Go to Step 3.
1. Turn the key switch to “OFF”.
2. Disconnect the AP sensor connector.
3. Connect the DMM between the AP sensor
3 power supply terminal and the ground. 4.5V
4. Turn the key switch to “ON”.
Is the DMM indication less than the specified
value? Go to Step 5. Go to Step 9.
1. Check the power supply circuit between
AP sensor 1 and ECM for short circuit to
the battery power supply circuit or ignition
power supply circuit using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.
4 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 9. Go to Step 6.
1. Check the power supply circuit between
AP sensor 1 and ECM for ground short
circuit using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

5 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 9. Go to Step 6.
6 Is EMPS available? — Go to Step 7. Go to Step 8.
1E-590 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

7 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 9. Go to Step 8.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 9. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
9 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1631 detected? Go to Step 2. Go to Step 10.
Check if other DTC is detected.
10 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-591
DTC: P1632 (Flash code 55) Voltage fault in 5-V power supply 2

A A Engine control
module (ECM)

Accelerator Accelerator
position position Barometric pressure Intake air temperature
sensor 1 signal sensor 2 signal sensor signal sensor signal
CAN LOW CAN HIGH
5V 5V

Vcc

37 E-57 18 E-57
20 E-57 41 E-57 63 E-57 64 E-57 42 E-57 60 E-57 71 E-57 61 E-57 72 E-57

Machine
control unit

CAN HIGH CAN LOW

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

6 FL-167 5 FL-167 4 FL-167 6 FL-167 5 FL-167 4 FL-167 2 FL-269 1 FL-269 3 FL-269 2 FB-124 1 FB-124

Accelerator position sensor Barometric Intake air

pressure sensor temperature sensor

TSHK0029

Description of circuit DTC set condition

The 5-V power supply circuit is provided to the ECM for • Key switch power supply voltage is 5.5 V or more,
5 systems. The 5-V power supply circuit 2 supplies or 4.5 V or less for 0.5 seconds or more.
power to the barometric pressure sensor.
The ECM sets the DTC when the voltage in the 2-V Action taken when DTC is set
power supply circuit 5 and 5 is higher or lower than the • Turns the diagnosis lamp ON.
normal range.
Back-up mode
Main trouble symptom
• Same to barometric pressure and intake air
Due to back-up equivalent to 2500 m (8200 ft) temperature sensor fault
• Black smoke emitted at high altitude
• Output shortage at low altitude Recovery from failure
Refer to “List of diagnostic trouble code” and “About
Preconditions when DTC is set recovery from failure” in this section for recovery from
• DTC P1630 is not detected. failure.
• Key switch input power supply voltage is higher
than 16 V but lower than 32 V.
1E-592 Electronic control fuel injection system (Common rail type)
The conditions to clear the MIL/DTC • Using the scan tool, or memory clear switch and
• The present trouble turns to history trouble when diagnostic switch operation enables to clear DTCs.
the condition is out of the range from DTC set
condition (recovery from failure). Test description
• The diagnosis lamp will go off after the code turns Numbers below indicate step numbers in the chart.
to history trouble and the key switch is turned 2. Measure at the harness connector-side.
“OFF” then “ON” again. 3. Measure at the harness connector-side.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Turn the key switch to “OFF”.
2. Disconnect the barometric pressure
sensor connector.
3. Connect the DMM between the barometric
2 pressure sensor power supply terminal 5.5V
and the ground.
4. Turn the key switch to “ON”.
Is the DMM indication more than the specified
value? Go to Step 4. Go to Step 3.
1. Turn the key switch to “OFF”.
2. Disconnect the barometric pressure
sensor connector.
3. Connect the DMM between the barometric
3 pressure sensor power supply terminal 4.5V
and the ground.
4. Turn the key switch to “ON”.
Is the DMM indication less than the specified Go to “Diagnostic
value? Go to Step 5. aid”.
1. Check the power supply circuit between
barometric pressure sensor and ECM for
short circuit to the battery power supply
circuit or ignition power supply circuit
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
4 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 9. Go to Step 6.
 Electronic control fuel injection system (Common rail type) 1E-593

Step Action Value YES NO

1. Check the power supply circuit between
barometric pressure sensor and ECM for
ground short circuit using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.
5 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 9. Go to Step 6.
6 Is EMPS available? — Go to Step 7. Go to Step 8.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
7 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 9. Go to Step 8.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 9. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
9 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1632 detected? Go to Step 2. Go to Step 10.
Check if other DTC is detected.
10 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1E-594 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.)

Vehicle speed Engine oil pressure

sensor signal 5V 5V sensor signal
5V

CKP CKP Engine coolant

Fuel temperature Vcc
HIGH LOW temperature sensor
signal signal sensor signal signal

108 E-56 107 E-56 106 E-56 19 E-57 83 E-56 84 E-56 79 E-56 67 E-56 80 E-56

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

3 H-20 2 H-20 1 H-20 0.75 0.75 0.75

B/Y L/Y W/B
0.75 Br
0.75 0.75 0.75 0.75
Pulse
Y/G B/Y R/B B/Y
0.75 0.75 matching
B/R W/L box
2 E-93 1 E-93 2 E-90 1 E-90 1 E-76 2 E-76 3 E-76

2 E-98 1 E-98

Engine
coolant
temperature
Fuel temperature sensor sensor Engine oil
pressure sensor
CKP sensor
A
Engine control
* 3 E-90 CAN LOW CAN HIGH module (ECM)
0.75
R

37 E-57 18 E-57
4 H-6

Vehicle
speed sensor A

Meter Machine
control
unit
CAN HIGH CAN LOW
Engine
coolant
temperature Machine trouble
gauge diagnosis monitor

TSHK0030

Description of circuit DTC set condition

The 5-V power supply circuit is provided to the ECM for • Key switch power supply voltage is 5.5 V or more,
5 systems. The 5-V power supply circuit 3 supplies or 4.5 V or less for 0.5 seconds or more.
power to the engine oil pressure sensor.
The ECM sets the DTC when the voltage in the 5-V Action taken when DTC is set
power supply circuit 3 is higher or lower than the normal • Turns the diagnosis lamp ON.
range.
Back-up mode
Main trouble symptom
• Same to coolant temperature, fuel temperature,
• Startability deteriorates at low temperatures. and oil pressure sensor fault
• Black smoke emission possible
• Operationality is affected. Recovery from failure
Refer to “List of diagnostic trouble code” and “About
Preconditions when DTC is set recovery from failure” in this section for recovery from
• DTC P1630 is not detected. failure.
• Key switch input power supply voltage is higher
than 16 V but lower than 32 V.
 Electronic control fuel injection system (Common rail type) 1E-595
The conditions to clear the MIL/DTC • Using the scan tool, or memory clear switch and
• The present trouble turns to history trouble when diagnostic switch operation enables to clear DTCs.
the condition is out of the range from DTC set
condition (recovery from failure). Test description
• The diagnosis lamp will go off after the code turns Numbers below indicate step numbers in the chart.
to history trouble and the key switch is turned 2. Measure at the harness connector-side.
“OFF” then “ON” again. 3. Measure at the harness connector-side.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Turn the key switch to “OFF”.
2. Disconnect the engine oil pressure sensor
connector.
3. Connect the DMM between the engine oil
2 pressure sensor power supply terminal 5.5V
and the ground.
4. Turn the key switch to “ON”.
Is the DMM indication more than the specified
value? Go to Step 4. Go to Step 3.
1. Turn the key switch to “OFF”.
2. Disconnect the engine oil pressure sensor
connector.
3. Connect the DMM between the engine oil
3 pressure sensor power supply terminal 4.5V
and the ground.
4. Turn the key switch to “ON”.
Is the DMM indication less than the specified Go to “Diagnostic
value? Go to Step 5. aid”.
1. Check the power supply circuit between
engine oil pressure sensor and ECM for
short circuit to the battery power supply
circuit or ignition power supply circuit
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
4 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 9. Go to Step 6.
1E-596 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the power supply circuit between
engine oil pressure sensor and ECM for
ground short circuit using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.
5 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 9. Go to Step 6.
6 Is EMPS available? — Go to Step 7. Go to Step 8.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
7 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 9. Go to Step 8.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 9. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
9 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1633 detected? Go to Step 2. Go to Step 10.
Check if other DTC is detected.
10 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-597
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

74 E-56 109 E-56 91 E-56 95 E-56

15 H-20 17 H-20 16 H-20 8 H-20

0.75 0.75 0.75 0.75 0.75

B/R R/L R/L L R/W

2 E-163 1 E-163 1 E-75 2 E-75 3 E-75

Boost temperature sensor

Boost pressure sensor

TSWG0079

Description of circuit DTC set condition

The 5-V power supply circuit is provided to the ECM for • Key switch power supply voltage is 5.5 V or more,
5 systems. The 5-V power supply circuit 4 supplies or 4.5 V or less for 0.5 seconds or more.
power to the boost pressure sensor.
The ECM sets the DTC when the voltage in the 5-V Action taken when DTC is set
power supply circuit 4 and 3 is higher or lower than the • Turns the diagnosis lamp ON.
normal range.
Back-up mode
Main trouble symptom
• Same to boost pressure and boost temperature
Operationality is affected. sensor fault

Preconditions when DTC is set Recovery from failure

• DTC P1630 is not detected. Refer to “List of diagnostic trouble code” and “About
• Key switch input power supply voltage is higher recovery from failure” in this section for recovery from
than 16 V but lower than 32 V. failure.
1E-598 Electronic control fuel injection system (Common rail type)
The conditions to clear the MIL/DTC • Using the scan tool, or memory clear switch and
• The present trouble turns to history trouble when diagnostic switch operation enables to clear DTCs.
the condition is out of the range from DTC set
condition (recovery from failure). Test description
• The diagnosis lamp will go off after the code turns Numbers below indicate step numbers in the chart.
to history trouble and the key switch is turned 2. Measure at the harness connector-side.
“OFF” then “ON” again. 3. Measure at the harness connector-side.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Turn the key switch to “OFF”.
2. Disconnect the boost pressure sensor
connector.
3. Connect the DMM between the boost
2 pressure sensor power supply terminal 5.5V
and the ground.
4. Turn the key switch to “ON”.
Is the DMM indication more than the specified
value? Go to Step 4. Go to Step 3.
1. Turn the key switch to “OFF”.
2. Disconnect the boost pressure sensor
connector.
3. Connect the DMM between the boost
3 pressure sensor power supply terminal 4.5V
and the ground.
4. Turn the key switch to “ON”.
Is the DMM indication less than the specified Go to “Diagnostic
value? Go to Step 5. aid”.
1. Check the power supply circuit between
boost pressure sensor and ECM for short
circuit to the battery power supply circuit or
ignition power supply circuit using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.
4 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 9. Go to Step 6.
 Electronic control fuel injection system (Common rail type) 1E-599

Step Action Value YES NO

1. Check the power supply circuit between
boost pressure sensor and ECM for
ground short circuit using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.
5 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 9. Go to Step 6.
6 Is EMPS available? — Go to Step 7. Go to Step 8.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
7 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 9. Go to Step 8.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 9. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
9 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1634 detected? Go to Step 2. Go to Step 10.
Check if other DTC is detected.
10 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1E-600 Electronic control fuel injection system (Common rail type)
DTC: P1635 (Flash code 55) Voltage fault in 5-V power supply 5

Engine control
module (ECM)

CMP sensor Common rail pressure EGR position EGR position EGR position
signal sensor signal sensor signal sensor signal sensor signal
5V

B+ B+ B+

99 E-56 98 E-56 100 E-56 101 E-56 82 E-56 90 E-56 87 E-56 92 E-56 110 E-56 93 E-56 103 E-56 94 E-56 111 E-56

3 H-8 7 H-8 2 H-8 6 H-8 1 H-8 5 H-8

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

0.75 0.75 0.75

W/R B/W Br 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
W G/Y W/L G/W W/B G/B W/R B

1 E-80 2 E-80 6 E-80 3 E-80 7 E-80 4 E-80 8 E-80 5 E-80

0.75 0.75 0.75 0.75
Br B G W

1 E-1122 E-112 3 E-112 1 E-113 2 E-113 3 E-113 W

V U

EGR position sensor/EGR motor

EGR valve

CMP sensor Common rail pressure sensor

TSHK0028

Description of circuit Preconditions when DTC is set

The 5-V power supply circuit is provided to the ECM for • DTC P1630 is not detected.
5 systems. The 5-V power supply circuit 5 supplies • Key switch input power supply voltage is higher
power to the common rail pressure sensor and the than 16 V but lower than 32 V.
EGR position sensor.
The ECM sets the DTC when the voltage in the 5-V DTC set condition
power supply circuit 5 and 2 is higher or lower than the
• Key switch power supply voltage is 5.5 V or more,
normal range.
or 4.5 V or less for 0.5 seconds or more.
Main trouble symptom
Action taken when DTC is set
• Engine blow up
• Turns the diagnosis lamp ON.
• Output lowering
• Black smoke emitted Back-up mode
• Engine stall possible • Same to rail pressure sensor fault and EGR
position sensor fault
 Electronic control fuel injection system (Common rail type) 1E-601
Recovery from failure • The diagnosis lamp will go off after the code turns
Refer to “List of diagnostic trouble code” and “About to history trouble and the key switch is turned
recovery from failure” in this section for recovery from “OFF” then “ON” again.
failure. • Using the scan tool, or memory clear switch and
diagnostic switch operation enables to clear DTCs.
The conditions to clear the MIL/DTC
Test description
• The present trouble turns to history trouble when
the condition is out of the range from DTC set Numbers below indicate step numbers in the chart.
condition (recovery from failure). 2. Measure at the harness connector-side.
3. Measure at the harness connector-side.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Connect the DMM between the common
2 rail pressure sensor power supply terminal 5.5V
and the ground.
4. Turn the key switch to “ON”.
Is the DMM indication more than the specified
value? Go to Step 4. Go to Step 3.
1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure
sensor connector.
3. Connect the DMM between the common
3 rail pressure sensor power supply terminal 4.5V
and the ground.
4. Turn the key switch to “ON”.
Is the DMM indication less than the specified Go to “Diagnostic
value? Go to Step 5. aid”.
1. Check the power supply circuit between
common rail pressure sensor and ECM for
short circuit to the battery power supply
circuit or ignition power supply circuit
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
4 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 9. Go to Step 6.
1E-602 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the power supply circuit between
common rail pressure sensor and ECM for
ground short circuit using breaker box or
DMM.
Refer to “Breaker box inspection
procedure”.
5 Note: —
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, repair as

required.
Is the trouble detected? Go to Step 9. Go to Step 61.
6 Is EMPS available? — Go to Step 7. Go to Step 8.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
7 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 9. Go to Step 8.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
8 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 9. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
9 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC P1635 detected? Go to Step 2. Go to Step 10.
Check if other DTC is detected.
10 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
 Electronic control fuel injection system (Common rail type) 1E-603
DTC: U2104 (Flash code 84) CAN Bus fault

Engine control
module (ECM)
CAN LOW CAN HIGH

KWP2000

52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57

1 FL-150 7 FL-150

DLC Machine
control unit

5 FL-150 4 FL-150

CAN HIGH CAN LOW

TSHK0023

Description of circuit Preconditions when DTC is set

The ECM communicates with the machine control unit • Key switch input voltage is 12V or more.
(ECU) through CAN communication circuit. The ECM
data outputs through the CAN-High circuit, and other Action taken when DTC is set
ECU data inputs through the CAN-Low circuit. The • Turns the diagnosis lamp ON.
CAN communication performs at a constant speed
without interruption, and the number of data outputs Back-up mode
and inputs must always be the same.
The ECM sets the DTC when the fault is detected for • Specified back-up value (depending on the
the CAN communication. machine manufacturer)

Main trouble symptom Recovery from failure

Vary depending on setting. Refer to “List of diagnostic trouble code” and “About
recovery from failure” in this section for recovery from
DTC set condition failure.

• Revolution command message of CAN

communication is disrupted for 1 second or more.
1E-604 Electronic control fuel injection system (Common rail type)
The conditions to clear the MIL/DTC Test description
• The present trouble turns to history trouble when Numbers below indicate step numbers in the chart.
the condition is out of the range from DTC set 2. If no DTC is detected, intermittent trouble is
condition (recovery from failure). suspected. Identify the cause by referring to
• Using the scan tool, or memory clear switch and “Diagnostic aid”.
diagnostic switch operation enables to clear DTCs. 5. Measure at the harness connector-side.

Step Action Value YES NO

Perform the OBD check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Turn the key switch to “OFF” for more than
10 seconds.
2 2. Start the engine. —
3. Check the DTC.
Go to “Diagnostic
Is DTC U2104 detected? Go to Step 3. aid”.
1. If the DTC U2104 is detected, and the
history and present troubles of
DTC U2106 are alternately detected,
check the circuit between ECM terminals
(32) and (18) for the following conditions.
3 • Short circuit —
2. If the trouble is detected, repair or replace
as required.
3. Check if DTC is not detected again.
Is the procedure completed? — Go to Step 4.
4 Is the breaker box available? — Go to Step 5. Go to Step 15.
1. Turn the key switch to “OFF”.
2. Remove the ECM.
3. Connect the breaker box to the ECM.
4. Connect the breaker box with the ECM
harness.
5. Measure the resistance between the CAN-
High-side terminal and CAN-Low-side
5 terminal using breaker box. 50 — 70Ω
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

Is the resistance within the specified value? Go to Step 13. Go to Step 6.

1. Remove the ECM from the breaker box.
2. Measure the resistance between the CAN-
High-side terminal and CAN-Low-side
terminal using breaker box.
Refer to “Breaker box inspection
6 procedure”. Approx. 120Ω
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

Is the resistance specified value? Go to Step 7. Go to Step 8.

 Electronic control fuel injection system (Common rail type) 1E-605

Step Action Value YES NO

1. Connect the ECM to the breaker box.
2. Remove the machine control unit and the
harness.
3. Measure the resistance between the CAN-
High-side terminal and CAN-Low-side
terminal using breaker box.
7 Refer to “Breaker box inspection Approx. 120Ω
procedure”.

Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

Is the resistance specified value? Go to Step 13. Go to Step 10.

1. Check the CAN-Low circuit and CAN-High
circuit between ECM and machine control
unit for short circuit to the power supply
circuit or ignition power supply circuit
using breaker box or DMM.
Refer to “Breaker box inspection
procedure”.
8 —
Note:
If breaker box is not available, refer to “On-
board check procedure for sensors”.

2. If the trouble is detected, replace the

harness.
Is the trouble detected? Go to Step 2. Go to Step 9.
1. Check for followings in the CAN-Low
circuit and CAN-High circuit between ECM
and machine control unit using breaker
box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
9 —
board check procedure for sensors”.

• Open circuit
• High resistance
• Short circuit to ground
2. If the trouble is detected, repair as
Replace the
required.
machine control
Is the trouble detected? Go to Step 2. unit.
10 Is EMPS available? — Go to Step 11. Go to Step 12.
1E-606 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

11 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Verify repair. Go to Step 12.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
13 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC U2104 detected? Go to Step 2. Go to Step 14.
Check if other DTC is detected.
14 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
Remove the ECM, and measure the resistance
between the CAN-High-side terminal and
15 CAN-Low-side terminal of the ECM connector. Approx. 120Ω

Is the resistance specified value? Go to Step 16. Go to Step 8.

1. Install the ECM, and remove the machine
control unit.
2. Measure the resistance between the CAN-
16 High-side terminal and CAN-Low-side Approx. 120Ω
terminal of the machine control unit
connector.
Is the resistance specified value? Go to Step 13. Go to Step 10.
 Electronic control fuel injection system (Common rail type) 1E-607
Breaker box inspection procedure
Perform the inspection in the following procedure if
there is such an instruction to use breaker box in the
step. After inspection, return to the diagnostic step.

Name
1. Breaker box
2. DMM

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
8 Short circuit to Voltage • Remove all the 18 - Ground 0V 18V or
power supply measurement relevant ECU 37 - Ground more
circuit connectors.
• Key switch “ON”
9 Open circuit/ Resistance • Remove all the 37 - Machine control 100Ω or 10 MΩ or
high measurement relevant ECU unit less more
resistance connectors. 18 - Machine control
• Key switch “OFF” unit
Short circuit to Resistance • Remove all the 18 - Ground 10 MΩ or 100Ω or
ground measurement relevant ECU 37 - Ground more less
connectors.
• Key switch “OFF”
1E-608 Electronic control fuel injection system (Common rail type)
DTC: U2106 (Flash code 85) CAN timeout fault

Engine control
module (ECM)
CAN LOW CAN HIGH

KWP2000

52 E-57 38 E-57 81 E-57 62 E-57 43 E-57 1 E-57 3 E-57 4 E-57 37 E-57 18 E-57

1 FL-150 7 FL-150

DLC Machine
control unit

5 FL-150 4 FL-150

CAN HIGH CAN LOW

TSHK0023

Description of circuit DTC set condition

The ECM communicates with the machine control unit • Instruction message on CAN communication to run
(ECU) through CAN communication circuit. The ECM is disrupted for 1 second or more.
data outputs through the CAN-High circuit, and other
ECU data inputs through the CAN-Low circuit. The Preconditions when DTC is set
CAN communication performs at a constant speed • DTC U2104 is not detected.
without interruption, and the number of data outputs
• Key switch input voltage is 20 V or more.
and inputs must always be the same.
The ECM sets the DTC when the CAN communication
Action taken when DTC is set
is disrupted with the machine control unit (ECU).
• Turns the diagnosis lamp ON.
Main trouble symptom
Back-up mode
• Vary depending on setting.
• It cannot be controlled from the machine side since • Specified back-up value (depending on the
CAN communication is disabled. The engine machine manufacturer)
speed becomes back-up speed specified by each
machine manufacturer.
 Electronic control fuel injection system (Common rail type) 1E-609
Recovery from failure Following inspections are necessary to detect these
Refer to “List of diagnostic trouble code” and “About causes.
recovery from failure” in this section for recovery from • Improper connection of harness connector and
failure. ECM connector
– Poor connection of terminal from connector
The conditions to clear the MIL/DTC – Unmatched terminals are fitted.
• The present trouble turns to history trouble when – Damage of connector lock
the condition is out of the range from DTC set – Poor contact between terminal and wire
condition (recovery from failure). • Damaged harness
• Using the scan tool, or memory clear switch and – Visually check the harness for damage.
diagnostic switch operation enables to clear DTCs.
– Check the relevant items on the scan tool data
display while moving the connector and the
Diagnostic aid
harness which are related to the sensor. The
If the intermittent trouble is suspected, followings may variation of the display indicates the faulty part.
be the cause.
• Improper connection of harness connector Test description
• Defective harness routing Numbers below indicate step numbers in the chart.
• Worn harness cladding 2. If no DTC is detected, intermittent trouble is
• Wire disconnection inside harness cladding suspected. Identify the cause by referring to
“Diagnostic aid”.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Turn the key switch to “OFF” for more than
10 seconds.
2 2. Start the engine. —
3. Check the DTC.
Go to “Diagnostic
Is DTC U2106 detected? Go to Step 3. aid”.
1. Check for followings in the CAN-Low
circuit and CAN-High circuit between ECM
and machine control unit (ECU) using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
3 If breaker box is not available, refer to “On- —
board check procedure for sensors”.

• Open circuit
• High resistance
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 11. Go to Step 4.
1E-610 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

1. Check for followings in the CAN-Low
circuit and CAN-High circuit between ECM
and machine control unit (ECU) using
breaker box or DMM.
Refer to “Breaker box inspection
procedure”.

Note:
If breaker box is not available, refer to “On-
4 —
board check procedure for sensors”.

• Short circuit to ground circuit

• Short circuit to power supply circuit or
ignition power supply circuit
2. If the trouble is detected, repair as
required.
Is the trouble detected? Go to Step 11. Go to Step 5.
Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
5 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Go to “Diagnostic
Is DTC U2106 detected? Go to Step 6. aid”.
1. If the DTC U2104 is detected, and the
history and present troubles of DTC
U2106 are alternately detected, check the
circuit between ECM terminals (32) and
(18) for the following conditions.
6 • Short circuit —
2. If the trouble is detected, repair or replace
as required.
3. Check if DTC is not detected again.
Is the procedure completed? — Go to Step 7.
Replace the machine control unit.
7 —
Is the procedure completed? Go to Step 11. —
8 Is EMPS available? — Go to Step 9. Go to Step 10.
 Electronic control fuel injection system (Common rail type) 1E-611

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

9 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. Go to Step 10.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
10 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 11. —

Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
11 DTCs. —
3. Turn the key switch to “OFF” for more than
10 seconds.
4. Test run with the “Preconditions when
DTC is set”.
5. Check the DTC.
Is DTC U2106 detected? Go to Step 2. Go to Step 12.
Check if other DTC is detected.
12 — Go to each DTC
Is other DTC detected? diagnosis. Verify repair.
1E-612 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

Step Item to be Inspection Measuring condition Terminal No. Normal Abnormal

checked method value value
4 Open circuit/ Resistance • Remove the 18 - Machine control 100Ω or 10 MΩ or
high measurement machine control unit (ECU) less more
resistance unit (ECU) connector terminal
connector. 37 - Machine control
• Key switch “OFF” unit (ECU)
connector terminal
5 Short circuit to Resistance • Remove the 18 - Ground 10 MΩ or 100Ω or
ground measurement machine control 37 - Ground more less
unit (ECU)
connector.
• Key switch “OFF”
Short circuit to Voltage • Remove the 18 - Ground 0V 18V or
power supply measurement machine control 37 - Ground more
circuit unit (ECU)
connector.
• Key switch “ON”
 Electronic control fuel injection system (Common rail type) 1E-613
List of trouble symptom

Symptom Description
Engine start failure Crank speed is slow.
Crank speed is normal but engine does not start (no first
combustion).
Engine starts (first combustion exists) but cannot maintain
stable engine speed, or no blow up.
Engine stall Engine cranks but take long time before start. It operates
eventually, or starts but stops immediately.
Engine hunting, rough idling Engine idle speed is rough, or idle speed changes. In a more
severe case, engine or machine vibrates. In any serious
situations, the engine stalls.
Engine output shortage, lag down Engine output is lower than expected, and output does not
change with the accelerator lever (throttle lever) released,
engine response deteriorates.
Exhaust gas contains a lot of white smoke. A lot of white smoke emitted while running.
Exhaust gas contains a lot of black smoke. A lot of black smoke emitted while running.
Noise Abnormal sound occurs from the engine.
Fuel consumption deteriorates. Fuel consumption is remarkably more than that indicated in
the machine’s manual. The situation shown here is that the
problem is not found on the machine side and the engine
needs to be checked.
Oil consumption deteriorates. Oil consumption is remarkably lower than that indicated in the
machine’s manual. The situation shown here is that the
problem is not found on the machine side and the engine
needs to be checked.
1E-614 Electronic control fuel injection system (Common rail type)
Engine start failure
Pre-inspection Diagnostic aid
Before using this paragraph, perform the “OBD system • If the crank sensor is faulty, crank more than 60
check” and check all the following items. rpm for 14 seconds or more since it is not judged
• Check if excessive load is applied to the machine on cranking for less than 14 revolutions.
side. • When the engine is running at low speed, the DTC
• ECM and diagnosis lamp operate properly. of crank sensor fault may not be detected. If an
• Check the DTC. intermittent trouble is found, raise the engine
speed up to No Load Max, and check if DTC
• Scan tool data shows normal operating range.
related to crank sensor is detected.
• Check the condition of the machine to identify the
• Fuel system fault (run out of fuel, frozen fuel, air
applicable symptom from “List of trouble
mixed in fuel pipe, faulty filter [clog in main filter,
symptom”. Perform the procedure described in the
gauze filter], pipe fault, fuel quality, fuel tank
symptom chart.
[foreign matter, fuel suction fault])
• Check with the customer if correct engine oil and
• Intake system fault (clogging in filter, intake pipe
fuel are used.
fault, etc.)
Visual check • Supply pump fault (no fuel pressure feed)
• Common rail fault (flow damper or pressure limiter
Careful visual check is required for some symptom
is activated, degradation of sealability)
procedures. By this inspection, the problem can be
corrected without performing further inspection, and • Injector fault (no fuel injection)
time can be saved. • System down due to trouble
This inspection includes the following items. • Engine body fault
This inspection includes the following items. (seizure, compression pressure shortage, other
• There is no dirt or clogging in fuel filter. mechanical trouble)
• There is no poor contact in connector (it must be • ACG trouble
connected with click sound). Especially for CKP • Machine side related equipment trouble
sensor and CMP sensor. (oil pressure pump etc.)
• The terminal voltage of battery is not low. • Effect of commercial electrical equipment (radio,
• Wire is connected, tightened or cut properly. lamp, etc.)
• Commercial accessory power supply is not • ECM trouble
bifurcated from ECM power supply. (body, power supply, ground, etc.)
• ECM ground is not contaminated and installed to • Check the connector for poor contact, the harness
the proper position securely. for fault such as wear or bend, and the wire inside
• Pipes and hoses relevant to fuel, air and oil are the harness for loosened wire causing short circuit
free of crack or twist, and are properly connected. to other circuits. Also, perform the function
Thoroughly check for any oil leakage and clogging. diagnosis to check the operation and control of
• Fuel system is free from oil leakage, and pipe is each part. Repair if faulty.
not damaged or dent.
• Intake system parts for fault.
• Exhaust system parts for fault.

Step Action Value YES NO

Is the emergency stop switch equipped? Turn the switch to
1 — “OFF”, and Go to
Step 2. Go to Step 2.
Perform the OBD system check.
2 — Go to “OBD
Is the procedure completed? Go to Step 3. system check”.
Check if DTC is detected.
Check if following DTCs are detected.
3 DTC: P0335, P0336, P0340, P0341, P0601, — Go to the related
P1261, P1262
“Inspection method
Is DTC detected? by DTC”. Go to Step 4.
 Electronic control fuel injection system (Common rail type) 1E-615

Step Action Value YES NO

Check the crank speed.
Check if the crank speed is more than the
4 necessary speed for ECM to identify engine 60 rpm
rotation.
Is the crank speed more than specified value? Go to Step 5. Go to Step 6.
Check the crank speed.
Check if the crank speed is more than the
5 necessary speed to start the engine (first 80 rpm
combustion).
Is the crank speed more than specified value? Go to Step 7. Go to Step 6.
Check the starting system.
6 — Go to “Starting
Is the procedure completed? Go to Step 7. system check”.
Check the fuel system in the following
procedure.
1. Check the high pressure pipe and low
pressure pipe for looseness in the
connection (fuel leakage), crush or
clogging.
Check the clogging in the following
procedure.
• Fuel filter (main fuel filter, pre-fuel filter,
gauze filter)
• Fuel tank (pump strainer)
7 • Fuel system pipe —
2. Check the fuel pipe, fuel filter, and inside
of the fuel tank for freeze or waxing. (at
cold temperature)
• If opaque frosty object is found in the
filter part of the main filter, waxing may
occurs. Replace fuel.
3. Check the feed pipe inside the fuel tank for
clogging of foreign matter.
4. Repair or replace the faulty part.
Is the procedure completed? Go to Step 8. —
1E-616 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the injector.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2. Start the engine.
3. Select the “Actuator test” from the scan
tool menu.
8 When the scan tool is not available, refer —
to “How to Inspect Injector” in this section.
4. Select the “Injection stop at each injector”
in the “Common rail system”.
5. Press the “OFF” soft key to stop the fuel
injection in the cylinder one by one, and
check the change in engine sound.
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 9. Go to Step 10.
Replace the injector in the cylinder of which
engine sound did not change when it is
stopped.

9 Note: —
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? — Go to Step 10.

Check the ACG.
Check if the charge warning lamp turns on
while engine is running.

10 Note: —
Refer to the machine’s manual for charge
warning.

Does the charge warning operate? Go to Step 12. Go to Step 11.

Replace the ACG. Also, check the charge
11 warning system, and repair or replace if faulty. —
Is the procedure completed? — Go to Step 12.
Check the condition of commercial electrical
equipment such as radio and lights.
12 —
Does the engine start when the commercial
electrical equipment is powered OFF? Go to Step 13. Go to Step 14.
Correct the installation condition of the
electrical equipment, or remove the electrical
13 equipment. —

Is the procedure completed? — Go to Step 14.

 Electronic control fuel injection system (Common rail type) 1E-617

Step Action Value YES NO

Check the mechanical part of the engine, and
repair if faulty.
• Compression pressure
• Valve system
• Injector
• Timing gear
14 • Related part of piston/crank —

Note:
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? — Go to Step 15.

15 Is EMPS available? — Go to Step 16. Go to Step 17.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
16 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Verify repair. Go to Step 16.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
17 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Verify repair. Go to Step 3.

1E-618 Electronic control fuel injection system (Common rail type)
Engine stall
Pre-inspection • Pipes and hoses relevant to fuel, air and oil are
Before using this paragraph, perform the “OBD system free of crack or twist, and are properly connected.
check” and check all the following items. Thoroughly check for any oil leakage and clogging.
• Check if excessive load is applied to the machine • Fuel system is free from oil leakage, and pipe is
side. not damaged or dent.
• ECM and diagnosis lamp operate properly. • Intake system parts for fault.
• To detect crank sensor fault, crank more than 60 • Exhaust system parts for fault.
rpm for 14 seconds or more since it is not judged
on cranking for less than 14 revolutions. Diagnostic aid
• Check the DTC. • Fuel system fault (run out of fuel, frozen fuel, air
• When the engine is running at low speed, the DTC mixed in fuel pipe, faulty filter [clog in main filter,
of crank sensor fault may not be detected. If an gauze filter], pipe fault, fuel quality, fuel tank
intermittent trouble is found, raise the engine [foreign matter, fuel suction fault])
speed up to No Load Max, and check if DTC • Intake system fault (clogging in filter, intake pipe
related to crank sensor is detected. fault, etc.)
• Scan tool data shows normal operating range. • Supply pump fault (no fuel pressure feed)
• Check the condition of the machine to identify the • Common rail fault (flow damper or pressure limiter
applicable symptom from “List of trouble is activated, degradation of sealability)
symptom”. Perform the procedure described in the • Injector fault (no fuel injection)
symptom chart. • System down due to trouble
• Check with the customer if correct engine oil and • Engine body fault
fuel are used. (seizure, compression pressure shortage, other
mechanical trouble)
Visual check • ACG trouble
Careful visual check is required for some symptom • Machine side related equipment trouble
procedures. By this inspection, the problem can be (oil pressure pump etc.)
corrected without performing further inspection, and
• Effect of commercial electrical equipment (radio,
time can be saved.
lamp, etc.)
This inspection includes the following items.
• ECM trouble
• There is no poor contact in connector (it must be
(body, power supply, ground, etc.)
connected with click sound). Especially for CKP
sensor and cam sensor. • Check the connector for poor contact, the harness
for fault such as wear or bend, and the wire inside
• Wire is connected, tightened or cut properly.
the harness for loosened wire causing short circuit
• Commercial accessory power supply is not to other circuits. Also, perform the function
bifurcated from ECM power supply. diagnosis to check the operation and control of
• ECM ground is not contaminated and installed to each part. Repair if faulty.
the proper position securely.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check if excessive load is applied to the
machine side.
Repair or replace the faulty part.

2 Note: —
Refer to the machine’s manual for check
and repair.

Is the procedure completed? Go to Step 3. —

 Electronic control fuel injection system (Common rail type) 1E-619

Step Action Value YES NO

Check the electrical system.
1. Crank sensor fault is not judged on
cranking for less than 14 revolutions.
Crank the engine at 60 rpm or more for 14
seconds or more, or raise the engine
speed up to No Load Max, and check if
DTC is detected.
2. Check the connectors of the ECM, fuel
pump, ACG and electronic governor for
poor contact or play.
3 —
Note:
Poor contact in the connector, especially
CKP sensor and CMP sensor, causes
engine stall. It must be connected with click
sound.

3. Check the harness for open or short

circuit.
4. Repair or replace the faulty part.
Is the procedure completed? Go to Step 4. —
Check the ACG.
Check if the charge warning lamp turns on
while engine is running.

4 Note: —
Refer to the machine’s manual for charge
warning.

Does the charge warning operate? Go to Step 6. Go to Step 5.

Replace the ACG. Also, check the charge
5 warning system, and repair or replace if faulty. —
Is the procedure completed? Go to Step 6. —
Check the condition of commercial electrical
equipment such as radio and lights.
6 —
Does the engine stall when the commercial
electrical equipment is powered OFF? Go to Step 7. Go to Step 8.
Correct the installation condition of the
electrical equipment, or remove the electrical
7 equipment. —

Is the procedure completed? Go to Step 8. —

1E-620 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the fuel system in the following
procedure.
1. Check the high pressure pipe and low
pressure pipe for looseness in the
connection (fuel leakage), crush or
clogging.
Check the clogging in the following
procedure.
• Fuel filter (main fuel filter, pre-fuel filter,
gauze filter)
8 —
• Fuel tank (pump strainer)
• Fuel system pipe
2. Check the fuel pipe, fuel filter, and inside
of the fuel tank for freeze or waxing. (at
cold temperature)
3. Check the feed pipe inside the fuel tank for
clogging of foreign matter.
4. Repair or replace the faulty part.
Is the procedure completed? Go to Step 9. —
Check the intake system.
9 — Go to “Intake
Is the procedure completed? Go to Step 10. system check”.
Check the exhaust system.
10 — Go to “Exhaust
Is the procedure completed? Go to Step 11. system check”.
Check the mechanical part of the engine, and
repair if faulty.
• Compression pressure
• Valve system
11 • Injector —
• Timing gear
• Related part of piston/crank
Is the procedure completed? Go to Step 12. —
12 Is EMPS available? — Go to Step 13. Go to Step 14.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
13 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Verify repair. Go to Step 14.

 Electronic control fuel injection system (Common rail type) 1E-621

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
14 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Verify repair. —

1E-622 Electronic control fuel injection system (Common rail type)
Engine hunting, rough idling
Pre-inspection • Fuel system is free from oil leakage, and pipe is
Before using this paragraph, perform the “OBD system not damaged or dent.
check” and check all the following items. • Intake system parts for fault.
• ECM and diagnosis lamp operate properly. • Exhaust system parts for fault.
• Check the DTC.
Diagnostic aid
• Scan tool data shows normal operating range.
• Check the condition of the machine to identify the • Fuel system fault (run out of fuel, frozen fuel, air
applicable symptom from “List of trouble mixed in fuel pipe, faulty filter [clog in main filter,
symptom”. Perform the procedure described in the gauze filter], pipe fault, fuel quality, fuel tank
symptom chart. [foreign matter, fuel suction fault])
• Check with the customer if correct engine oil and • Intake system fault (clogging in filter, intake pipe
fuel are used. fault, etc.)
• Supply pump (including feed pump) fault (no fuel
Visual check pressure feed)
Careful visual check is required for some symptom • Switch input circuit system fault
procedures. By this inspection, the problem can be • Sensor input circuit system fault (accelerator
corrected without performing further inspection, and position (AP) sensor, harness, engine coolant
time can be saved. temperature (ECT) sensor, etc.)
This inspection includes the following items. • AP sensor system fault (sensor, harness, etc.)
• There is no poor contact in connector (it must be • Engine body fault (seizure, compression pressure
connected with click sound). shortage, other mechanical trouble)
• The terminal voltage of battery is not low. • Machine side related equipment trouble (oil
• Wire is connected, tightened or cut properly. pressure pump etc.)
• Commercial accessory power supply is not • Effect of commercial electrical equipment (radio,
bifurcated from ECM power supply. lamp, etc.)
• ECM ground is not contaminated and installed to • Check the connector for poor contact, the harness
the proper position securely. for fault such as wear or bend, and the wire inside
• Pipes and hoses relevant to fuel, air and oil are the harness for loosened wire causing short circuit
free of crack or twist, and are properly connected. to other circuits. Also, perform the function
Thoroughly check for any oil leakage and clogging. diagnosis to check the operation and control of
each part. Repair if faulty.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check if excessive load is applied to the
machine side.
Repair or replace the faulty part.

2 Note: —
Refer to the machine’s manual for check
and repair.

Is the procedure completed? Go to Step 3. —

Check the fuel.
1. Supply fuel from a container other than the
fuel tank.
3 2. Start the engine, operate the machine, and —
check for trouble symptom.
3. Replace the fuel in the fuel tank and pipe.
Is the engine symptom corrected? Go to Step 24. Go to Step 4.
 Electronic control fuel injection system (Common rail type) 1E-623

Step Action Value YES NO

Bleed air from fuel, and check for trouble
symptom again.

Note:
4 —
For work procedure, refer to “Engine
section” in the service manual.

Is the engine symptom corrected? Go to Step 24. Go to Step 5.

Check the intake system.
5 — Go to “Intake
Is the procedure completed? Go to Step 6. system check”.
Check the fuel system.
6 — Go to “Fuel system
Is the procedure completed? Go to Step 7. check”.
Check the injector.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2. Start the engine.
3. Select the “Actuator test” from the scan
tool menu.
7 When the scan tool is not available, refer —
to “How to Inspect Injector” in this section.
4. Select the “Injection stop at each injector”
in the “Common rail system”.
5. Press the “OFF” soft key to stop the fuel
injection in the cylinder one by one, and
check the change in engine sound.
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 9. Go to Step 8.
Replace the injector in the cylinder of which
engine sound did not change when it is
stopped.

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

Is the procedure completed? Go to Step 9. —

Check for the engine symptom again.
9 —
Is the engine symptom corrected? Go to Step 22. Go to Step 10.
Check the condition of commercial electrical
equipment such as radio and lights.
10 Does the engine symptom change when the —
commercial electrical equipment is powered
OFF? Go to Step 11. Go to Step 12.
Correct the installation condition of the
electrical equipment, or remove the electrical
11 equipment. —

Is the procedure completed? Go to Step 12. —

1E-624 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check for installation condition of the
crankshaft position (CKP) sensor and camshaft
position (CMP) sensor.
12 Check the CKP sensor and CMP sensor for —
improper installation such as play.
Is it properly installed? Go to Step 14. Go to Step 13.
Correct the installation conditions of the CKP
13 sensor and CMP sensor. —
Is the procedure completed? Go to Step 14. —
14 Is the scan tool available? — Go to Step 15. Go to Step 16.
Check the signal conditions of CKP sensor and
CMP sensor using scan tool.
1. Connect the scan tool.
15 2. Crank the engine. —
3. Correct the data list on the scan tool.
Is the speed displayed? Go to Step 18. Go to Step 16.
Check for signal detection condition of the CKP
sensor.
1. Start the engine.
2. Remove the harness from the CMP
16 sensor. —
(The DTC is detected when this procedure
is performed. Be sure to clear the DTC
after repairing the machine.)
Is the idle condition normal? Go to Step 23. Go to Step 17.
Check for signal detection condition of the
CMP sensor.
1. Start the engine.
2. Remove the harness from the CKP
17 sensor. —
(The DTC is detected when this procedure
is performed. Be sure to clear the DTC
after repairing the machine.)
Is the idle condition normal? Go to Step 23. Go to Step 18.
Check for the engine symptom again.
18 —
Is the engine symptom corrected? Go to Step 24. Go to Step 19.
19 Is EMPS available? — Go to Step 20. Go to Step 21.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

20 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 24. Go to Step 21.

 Electronic control fuel injection system (Common rail type) 1E-625

Step Action Value YES NO

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
21 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 24. Go to Step 22.

Restore the ECM to its original condition of
before replacement.

Note:
EGR valve position learning is required
22 after replacing or rewriting the ECM. —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 23. —

Check the mechanical part of the engine, and
repair if faulty.
• Compression pressure
• Valve system
23 • Flywheel —
• Camshaft gear
• Timing gear
• Related part of piston/crank
Is the procedure completed? Go to Step 24. Go to Step 2.
Repair the machine, and check the repair.
24 —
Is the procedure completed? Verify repair. —
1E-626 Electronic control fuel injection system (Common rail type)
Engine output shortage
Pre-inspection • Sensor input circuit system fault (accelerator
Before using this paragraph, perform the “OBD system position (AP) sensor, harness, etc.)
check” and check all the following items. • Switch input circuit system fault
• ECM and diagnosis lamp operate properly. • Engine body fault (compression pressure, valve
• Check the DTC. clearance, turbocharger, supply pump, injector,
common rail and other mechanical trouble, etc.)
• Scan tool data shows normal operating range.
• Machine side related equipment trouble (oil
• Check the condition of the machine to identify the
pressure pump etc.)
applicable symptom from “List of trouble
symptom”. Perform the procedure described in the • Effect of commercial electrical equipment (radio,
symptom chart. lamp, etc.)
• Check with the customer if correct engine oil and • Check the connector for poor contact, the harness
fuel are used. for fault such as wear or bend, and the wire inside
Various kinds of causes are assumed for output the harness for loosened wire causing short circuit
shortage, therefore thoroughly investigate the relation to other circuits. Also, perform the function
between engine body and machine. diagnosis to check the operation and control of
each part. Repair if faulty.
• Check what operation triggers the output shortage.
If hesitations or lag down is included in the symptom of • Output lowering due to regulated fuel flow during
the output shortage, the fault is related to the machine- overheat
side control. Contact with the machine manufacturer. Control during overheat
If Tech2 is available, checking the boost of Q enables to In overheating, ECM begins to limit fuel flow when the
check the engine output at rated point as a simplified engine coolant temperature exceeds 108°C (226°F), for
method. engine protection. It limits fuel flow further as the
engine coolant temperature goes up. Fuel flow is
Visual check limited to a certain level at around 120°C (248°F)*. (*
Careful visual check is required for some symptom Setting varies depending on the machine manufacturer)
procedures. By this inspection, the problem can be The system raises an alarm from 105°C (221°F) for
corrected without performing further inspection, and some machines. In addition to alarm, by reducing the
time can be saved. load to the machine, it enables to avoid such conditions
This inspection includes the following items. that the fuel flow is limited.
• There is no dirt or clogging in air cleaner element.
• Wire is connected, tightened or cut properly.
• Commercial accessory power supply is not
bifurcated from ECM power supply.
• ECM ground is not contaminated and installed to
the proper position securely.
(226 )
• Pipes and hoses relevant to fuel, air and oil are 100%

free of crack or twist, and are properly connected.

Thoroughly check for any oil leakage and clogging.
Fuel fiow

• Fuel system is free from oil leakage, and pipe is

not damaged or dent. (248 )

• Increase in resistance due to dirt or clogging in

intake system parts (especially air cleaner
element) and crushed intake pipes
• Exhaust system parts for fault. (221 )
Engine coolant temperature
Diagnostic aid
TSWG0169
• Fuel system fault (run out of fuel, frozen fuel, air
mixed in fuel pipe, faulty filter [clog in main filter,
gauze filter], pipe fault, fuel quality, fuel tank
[foreign matter, fuel suction fault])
• Intake system fault (clogging in filter, intake pipe
fault, etc.)
• Exhaust system fault (exhaust brake, exhaust pipe
fault, etc.)
 Electronic control fuel injection system (Common rail type) 1E-627
About high-altitude correction
ECM calculates the current altitude based on the
barometric pressure sensor signal.
It regulates the opening/closing period of PCV or
electric conduction of injector according to the altitude
etc. at this time, to correct the optimum fuel flow.
Fuel flow limit (mm 3/st)

Barometric pressure kPa(psi)

highland
TSWG0173

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
1. Make sure that the engine coolant
temperature does not exceed 108°C
(226°F).
2. Examine and repair the cause of overheat.
2 3. Lower the engine coolant temperature to —
make sure that the output lowering has
corrected.
Is the procedure completed? Go to Step 22. Go to Step 3.
Check driving environment.
Fuel flow may be limited by correction when Contact the
3 driving at high altitude. — machine
manufacturer for
Did you drive at high altitude? countermeasure. Go to Step 4.
Check if excessive load is applied to the
machine side.
Repair or replace the faulty part.

4 Note: —
Refer to the machine’s manual for check
and repair.

Is the procedure completed? Go to Step 5. —

Check the fuel.
1. Replace the fuel in the fuel tank and pipe.
5 2. Start the engine, operate the machine, and —
check for trouble symptom.
Is the engine symptom corrected? Go to Step 22. Go to Step 6.
1E-628 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Bleed air from fuel, and check for trouble
symptom again.

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

Is the engine symptom corrected? Go to Step 22. Go to Step 7.

Check the fuel system.
7 — Go to “Fuel system
Is the procedure completed? Go to Step 8. check”.
Check the intake system.
8 — Go to “Intake
Is the procedure completed? Go to Step 9. system check”.
Check the exhaust system.
9 — Go to “Exhaust
Is the procedure completed? Go to Step 10. system check”.
Check for the engine symptom again.
10 —
Is the engine symptom corrected? Go to Step 22. Go to Step 11.
Check the condition of commercial electrical
equipment such as radio and lights.
11 Does the engine symptom change when the —
commercial electrical equipment is powered
OFF? Go to Step 12. Go to Step 13.
Correct the installation condition of the
electrical equipment, or remove the electrical
12 equipment. —

Is the procedure completed? Go to Step 13. —

Check for the engine symptom again.
13 —
Is the engine symptom corrected? Go to Step 22. Go to Step 14.
Check the injector.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2. Start the engine.
3. Select the “Actuator test” from the scan
tool menu.
14 When the scan tool is not available, refer —
to “How to Inspect Injector” in this section.
4. Select the “Injection stop at each injector”
in the “Common rail system”.
5. Press the “OFF” soft key to stop the fuel
injection in the cylinder one by one, and
check the change in engine sound.
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 15. Go to Step 16.
 Electronic control fuel injection system (Common rail type) 1E-629

Step Action Value YES NO

Replace the injector in the cylinder of which
engine sound did not change when it is
stopped.

15 Note: —
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? Go to Step 15. —

16 Is EMPS available? — Go to Step 17. Go to Step 18.
1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

Note:
17 —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 20. Go to Step 18.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
18 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 20. Go to Step 19.

Restore the ECM to its original condition of
before replacement.

Note:
EGR valve position learning is required
19 after replacing or rewriting the ECM. —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 20. —

Check the mechanical part of the engine, and
repair if faulty.
• Compression pressure
• Valve system
20 • Injector —
• Timing gear
• Related part of piston/crank
Is the procedure completed? Go to Step 21. —
Check the machine-side equipment (trouble of
21 oil pressure pump etc.), and repair if faulty. —
Is the procedure completed? Go to Step 22. —
1E-630 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Repair the machine, and check the repair.
22 —
Is the procedure completed? Verify repair. —
 Electronic control fuel injection system (Common rail type) 1E-631
Exhaust gas contains a lot of white smoke.
Pre-inspection • Commercial accessory power supply is not
Before using this paragraph, perform the “OBD system bifurcated from ECM power supply.
check” and check all the following items. • ECM ground is not contaminated and installed to
• ECM and diagnosis lamp operate properly. the proper position securely.
• Check the DTC. • Pipes and hoses relevant to fuel, air and oil are
free of crack or twist, and are properly connected.
• Scan tool data shows normal operating range.
Thoroughly check for any oil leakage and clogging.
• Check the condition of the machine to identify the
• Fuel system is free from oil leakage, and pipe is
applicable symptom from “List of trouble
not damaged or dent.
symptom”. Perform the procedure described in the
symptom chart. • Intake system parts for fault.
• Check with the customer if correct engine oil and • Exhaust system parts for fault.
fuel are used.
Diagnostic aid
Visual check • Fuel quality (use of fuel other than specified)
Careful visual check is required for some symptom • Long-term idling
procedures. By this inspection, the problem can be • Trouble of engine coolant temperature (ECT)
corrected without performing further inspection, and sensor, fuel temperature (FT) sensor, intake air
time can be saved. temperature (IAT) sensor, boost pressure sensor,
This inspection includes the following items. or barometric pressure sensor.
• There is no poor contact in injector connector (it • Engine body trouble (compression pressure
must be connected with click sound). shortage, related to piston, turbocharger, rise/
• Wire is connected, tightened or cut properly. decline of oil, etc.)
• ECM trouble (body, power supply, ground, etc.)

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check the fuel.
1. Replace the fuel tank and the fuel in the
pipe, or supply the specified oil suitable for
current environment from the fuel
2 container. —
2. Start the engine, operate the machine, and
check for trouble symptom.
Is the engine symptom corrected? Go to Step 17. Go to Step 3.
Check the fuel system.
3 — Go to “Fuel system
Is the procedure completed? Go to Step 4. check”.
Check if oil is mixed in the intake air.
1. Is the blow-by emitted excessively?
• Excessive engine oil
• Clogged or deformed oil return pipe
4 • Clogged or crushed breather hose —
2. Wear of turbocharger seal ring
3. Repair or replace the faulty part.
Is the procedure completed? Go to Step 5. —
5 Is the scan tool available? — Go to Step 6. Go to Step 8.
1E-632 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check the injector.
1. Clear the DTC.
Refer to “How to clear diagnosis trouble
code (DTC)” of “Procedure of trouble
diagnosis” in this section for how to clear
DTCs.
2. Start the engine.
3. Select the “Actuator test” from the scan
6 tool menu. —
4. Select the “Injection stop at each injector”
in the “Common rail system”.
5. Press the “OFF” soft key to stop the fuel
injection in the cylinder one by one, and
check the change in engine sound.
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 9. Go to Step 7.
Perform the pre-injection stop test.
Select the “Stop pre-injection” from the scan
tool menu to perform the test.
7 —
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 9. Go to Step 10.
Check the injector using injector checker.
Refer to “How to use injector checker” in this
section for how to use injector checker.
8 —
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 9. Go to Step 10.
Replace the injector in the cylinder of which
engine sound did not change when it is
stopped.

9 Note: —
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? Go to Step 10. —

Check for the engine symptom again.
10 —
Is the engine symptom corrected? Go to Step 16. Go to Step 11.
11 Is EMPS available? — Go to Step 12. Go to Step 13.
 Electronic control fuel injection system (Common rail type) 1E-633

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

12 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 15. Go to Step 13.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
13 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 15. Go to Step 14.

Restore the ECM to its original condition of
14 before replacement. —
Is the procedure completed? Go to Step 15. —
Check the mechanical part of the engine, and
repair if faulty.
• Compression pressure
• Valve system
15 • Injector —
• Timing gear
• Related part of piston/crank
Is the procedure completed? Go to Step 16. —
Repair the machine, and check the repair.
16 —
Is the procedure completed? Verify repair. Go to Step 2.
1E-634 Electronic control fuel injection system (Common rail type)
Exhaust gas contains a lot of black smoke.
Pre-inspection • ECM ground is not contaminated and installed to
Before using this paragraph, perform the “OBD system the proper position securely.
check” and check all the following items. • Pipes and hoses relevant to fuel, air and oil are
• ECM and diagnosis lamp operate properly. free of crack or twist, and are properly connected.
Thoroughly check for any oil leakage and clogging.
• Check the DTC.
• Fuel system is free from oil leakage, and pipe is
• Scan tool data shows normal operating range.
not damaged or dent.
• Check the condition of the machine to identify the
• Intake system parts for fault.
applicable symptom from “List of trouble
symptom”. Perform the procedure described in the • Exhaust system parts for fault.
symptom chart.
Diagnostic aid
• Check with the customer if correct engine oil and
fuel are used. • Fuel quality (use of fuel other than specified)
• Intake system fault (clogging in filter, intake pipe
Visual check fault, etc.)
Careful visual check is required for some symptom • EGR control system fault
procedures. By this inspection, the problem can be • Exhaust system fault (exhaust pipe fault etc.)
corrected without performing further inspection, and • Engine coolant temperature (ECT) sensor fault
time can be saved. • Boost pressure sensor fault (sensor, pipe, etc.)
This inspection includes the following items.
• Engine body trouble (compression pressure
• There is no dirt or clogging in air cleaner element. shortage, related to the piston, turbocharger, rise of
• Wire is connected, tightened or cut properly. oil)
• Commercial accessory power supply is not
bifurcated from ECM power supply.

Step Action Value YES NO

Perform the OBD system check.
1 — Go to “OBD
Is the procedure completed? Go to Step 2. system check”.
Check the intake system.
2 — Go to “Intake
Is the procedure completed? Go to Step 3. system check”.
Check the EGR control system.
3 — Go to “EGR control
Is the procedure completed? Go to Step 4. system check”.
Check the reed valve of the EGR.
4 If the trouble is detected, repair as required. —
Is the procedure completed? Go to Step 5. —
Check the fuel system.
5 — Go to “Fuel system
Is the procedure completed? Go to Step 6. check”.
Check the exhaust system.
6 — Go to “Exhaust
Is the procedure completed? Go to Step 7. system check”.
Check for the engine symptom again.
7 —
Is the engine symptom corrected? Go to Step 15. Go to Step 8.
Check the mechanical part of the engine, and
repair if faulty.
8 • Valve system (valve clearance) —

Is the procedure completed? Go to Step 9. —

Check for the engine symptom again.
9 —
Is the engine symptom corrected? Go to Step 15. Go to Step 10.
10 Is EMPS available? — Go to Step 11. Go to Step 12.
 Electronic control fuel injection system (Common rail type) 1E-635

Step Action Value YES NO

1. Check the version of ECM software.
2. Rewrite the software if version upgraded is
necessary.
Refer to “How to use flash tool” in this section
for check and rewriting of ECM.

11 Note: —
EGR valve position learning is required
after replacing or rewriting the ECM.
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. Go to Step 12.

Replace the ECM.

Note:
EGR valve position learning is required
after replacing or rewriting the ECM.
12 —
Refer to “Engine Control System, Engine
control module (ECM), Installation of ECM”
in this section for learning of EGR.

Is the procedure completed? Go to Step 13. —

Check for the engine symptom again.
13 —
Is the engine symptom corrected? Go to Step 15. Go to Step 14.
Check the mechanical part of the engine, and
repair if faulty.
• Compression pressure
• Valve system
14 • Injector —
• Timing gear
• Related part of piston/crank
Is the procedure completed? Go to Step 15. —
Repair the machine, and check the repair.
15 —
Is the procedure completed? Verify repair. —
1E-636 Electronic control fuel injection system (Common rail type)
EGR valve check

TSWG0150

Push the EGR valve with finger to make sure it opens/

closes smoothly. Also, make sure that the valve closes
completely when the finger is released.
 Electronic control fuel injection system (Common rail type) 1E-637
Noise
Pre-inspection • Pipes and hoses relevant to fuel, air and oil are
Before using this paragraph, perform the “OBD system free of crack or twist, and are properly connected.
check” and check all the following items. Thoroughly check for any oil leakage and clogging.
• Check for noise by referring to the machine’s • Fuel system is free from oil leakage, and pipe is
manual. not damaged or dent.
• ECM and diagnosis lamp operate properly. • Intake system parts for fault.
• Check the DTC. • Exhaust system parts for fault.
• Scan tool data shows normal operating range.
Diagnostic aid
• Check the condition of the machine to identify the
applicable symptom from the table of contents. • Fuel system fault (run out of fuel, frozen fuel, air
Perform the procedure described in the symptom mixed in fuel pipe, faulty filter [clog in main filter,
chart. gauze filter], pipe fault, fuel quality, fuel tank
[foreign matter, fuel suction fault])
• Check with the customer if correct engine oil and
fuel are used. • Intake system fault (EGR valve fault)
• Injector fault (no fuel injection)
Visual check • Engine body fault (seizure, compression pressure
Careful visual check is required for some symptom shortage, other mechanical trouble)
procedures. By this inspection, the problem can be • Machine side related equipment trouble (oil
corrected without performing further inspection, and pressure pump etc.)
time can be saved. This inspection includes the • ECM trouble (body, power supply, ground, etc.)
following 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
diagnosis to check the operation and control of
each part. Repair if faulty.

Step Action Value YES NO

Identify the source of the noise and confirm the
1 noise. — Repair or replace
Is the noise metallic noise? the faulty parts. Go to Step 2.
2 Is the scan tool available? — Go to Step 3. Go to Step 8.
Perform the pre-injection stop test.
Select the “Stop pre-injection” from the scan
tool menu to perform the test.
3 —
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 5. Go to Step 4.
Perform “Injection Stop for Each Injector”.
1. Select the “Actuator test” from the scan
tool menu.
2. Select the “Injection stop at each injector”
in the “Common rail system”.
4 3. Press the “OFF” soft key to stop the fuel —
injection in the cylinder one by one, and
check the change in engine sound.
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 5. Go to Step 6.
1E-638 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Replace the injector in the cylinder of which
engine sound did not change when it is
stopped.

5 Note: —
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? Verify repair. —

Check the EGR valve.
• Fault in reed valve
6 • Fault in EGR valve body —
Repair or replace the faulty part.
Is the procedure completed? Verify repair. Go to Step 7.
Refer to “Engine section” in the service manual
to check the engine trouble.
7 Repair or replace the faulty part. —

Is the procedure completed? Verify repair. —

Check the injector using injector checker.
Refer to “How to use injector checker” in this
section for how to use injector checker.
8 —
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 5. Go to Step 6.
 Electronic control fuel injection system (Common rail type) 1E-639
Fuel consumption deteriorates.
Pre-inspection • Wire is connected, tightened or cut properly.
Before using this paragraph, perform the “OBD system • ECM ground is not contaminated and installed to
check” and check all the following items. the proper position securely.
• Fuel consumption varies depending on handling of • Pipes and hoses relevant to fuel, air and oil are
each machine. Check the machine manufacturer’s free of crack or twist, and are properly connected.
measure of fuel consumption (A). Thoroughly check for any oil leakage and clogging.
Measure of fuel consumption (2{qts}/hour) • Fuel system is free from oil leakage, and pipe is
• Check the actual fuel consumption (B). not damaged or dent.
Actual fuel consumption (2{qts}/hour) • Intake system parts for fault.
• If B is bigger than A, check the machine’s setting • Exhaust system parts for fault.
by referring to the machine’s manual.
• Check if excessive load is applied to the machine. Diagnostic aid
• Refer to the list of inspection and maintenance • Fuel system fault (run out of fuel, frozen fuel, air
items of the operation manual for proper inspection mixed in fuel pipe, faulty filter [clog in main filter,
depending on the operation time. gauze filter], pipe fault, fuel quality, fuel tank
• If the operation time exceeds 3000 hours, inspect [foreign matter, fuel suction fault])
by referring to the machine’s manual. • Intake system fault (EGR valve fault)
• ECM and diagnosis lamp operate properly. • Injector fault (excessive fuel injection etc.)
• Check the DTC. • Engine body fault (seizure, compression pressure
• Check the condition of the machine to identify the shortage, other mechanical trouble)
applicable symptom from “List of trouble • Machine side related equipment trouble (oil
symptom”. Perform the procedure described in the pressure pump etc.)
symptom chart. • ECM trouble (body, power supply, ground, etc.)
• Check with the customer if correct engine oil and • Check the connector for poor contact, the harness
fuel are used. for fault such as wear or bend, and the wire inside
• Check if periodic maintenance has been performed the harness for loosened wire causing short circuit
for engine oil replacement, air cleaner filter, fuel to other circuits. Also, perform the function
filter, etc. diagnosis to check the operation and control of
each part. Repair if faulty.
Visual check
Careful visual check is required for some symptom
procedures. By this inspection, the problem can be
corrected without performing further inspection, and
time can be saved. This inspection includes the
following items.

Step Action Value YES NO

1. Compare the measure of fuel consumption
with the actual fuel consumption.
A: Measure of fuel consumption (2{qts}/
hour)
B: Actual fuel consumption (2{qts}/hour)
1 2. If B is bigger than A, check the machine’s —
setting or if excessive load is applied to
the machine by referring to the machine’s
manual.
3. Repair or replace the faulty part.
Is the procedure completed? Verify repair. Go to Step 2.
Check for fuel leakage.
2 Repair or replace the faulty part. —
Is the procedure completed? Verify repair. Go to Step 3.
1E-640 Electronic control fuel injection system (Common rail type)

Step Action Value YES NO

Check if periodic maintenance has been
performed for engine oil replacement, air
3 — Perform
cleaner filter, fuel filter, etc.
maintenance for
Is the procedure completed? the machine. Go to Step 4.
Check the intake system and intercooler for
4 water accumulation. — Go to “Intake
Is the procedure completed? Go to Step 5. system check”.
Check the exhaust system for crush, bent or
5 clogging. — Go to “Exhaust
Is the procedure completed? Go to Step 6. system check”.
Check for output shortage. Go to “Output
6 — shortage, lag
Is the procedure completed?
Go to Step 7. down”.
Check if the engine oil of viscosity mentioned
Replace with the
7 in the operation manual is used. — appropriate oil, and
Is the appropriate oil used? Go to Step 8. Go to Step 1.
Check the cooling fan for fault.
8 Repair or replace the faulty part. —
Is the procedure completed? Go to Step 9. —
Is the scan tool (KW communication)
9 —
available? Go to Step 10. Go to Step 15.
Perform “Injection Stop for Each Injector”.
1. Select the “Actuator test” from the scan
tool menu.
2. Select the “Injection stop at each injector”
in the “Common rail system”.
10 3. Press the “OFF” soft key to stop the fuel —
injection in the cylinder one by one, and
check the change in engine sound.
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 11. Go to Step 12.
Replace the injector in the cylinder of which
engine sound did not change when it is
stopped.

11 Note: —
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? Go to Step 12. —

Check the engine compression pressure.
12 Repair or replace the faulty part. —
Is the procedure completed? Go to Step 13. —
Check the valve clearance.
13 Repair or replace the faulty part. —
Is the procedure completed? Go to Step 14. —
 Electronic control fuel injection system (Common rail type) 1E-641

Step Action Value YES NO

Has the engine operated for more than 3000
hours?
If more than 3000 hours, check or repair the
14 engine friction by referring to “Engine section” —
in the service manual.
Is the procedure completed? Verify repair. —
Check the injector using injector checker. Refer
to “How to use injector checker” in this section
for how to use injector checker.
15 —
Is there any cylinder of which engine vibration
and engine sound did not change when it is
stopped? Go to Step 11. Go to Step 12.

Inspection location of engine intake/exhaust system

3 1

6 7 8 9 10

TSWG0163

Name
1. Exhaust pipe 6. Secondary EGR cooler
2. To intercooler 7. From intercooler
3. From air cleaner 8. EGR valve
4. EGR duct 9. EGR duct
5. Primary EGR cooler 10. EGR duct

Check the above intake/exhaust system for fault such as clogging, crush or breakage.
Besides the inspection location of engine body, check the air cleaner, intercooler and muffler.
1E-642 Electronic control fuel injection system (Common rail type)
Oil consumption deteriorates.
Pre-inspection Visual check
Before using this paragraph, perform the “OBD system Careful visual check is required for some symptom
check” and check all the following items. procedures. By this inspection, the problem can be
• Oil consumption varies depending on handling of corrected without performing further inspection, and
each machine. Check the machine manufacturer’s time can be saved. This inspection includes the
measure of oil consumption (A). following items.
Measure of oil consumption/hour • If bluish-white smoke is emitted continuously while
Measure of oil consumption for engine alone: engine running.
42{4.2qts}/100 hours • If blow-by gas is emitted.
• Check the actual oil consumption (B). • If oil is mixed in the coolant.
Actual oil 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
fuel are used. operation and control of each part. Repair if faulty.

Step Action Value YES NO

Check the following for trouble occurrence:
• Engine speed
• Operational pattern (continuous/intermittent)
• Operating load (mode in use)
• Oil consumption /hour
• If more than 100 hours has elapsed since
initial operation.
1 Compare with the specified value of oil —
consumption by referring to the machine’s
manual.

Note:
Use the operation mode mentioned in the
machine’s manual to make comparison.
Explain this to the
Is the oil consumption within specified value? customer. Go to Step 2.
Check for oil leakage. Repair or replace the
2 faulty part. —
Is the procedure completed? Verify repair. Go to Step 3.
Check if bluish-white smoke is emitted while
engine running.
3 If it is emitted only at the starting, go to —
“Exhaust gas contains a lot of white smoke.”
Is bluish-white smoke emitted? Go to Step 4. Go to Step 6.
Check the blow-by gas quantity.
4 —
Is it more than the specified value? Go to Step 7. Go to Step 5.
 Electronic control fuel injection system (Common rail type) 1E-643

Step Action Value YES NO

Check for oil leakage from the turbocharger.
5 Repair or replace the faulty part. —
Is the procedure completed? Verify repair. Go to Step 6.
Check if oil is mixed in the coolant.
6 —
Is oil mixed in the coolant? Go to Step 10. Go to Step 11.
Check the engine compression pressure.
7 Repair or replace the faulty part. —
Is the trouble detected? Go to Step 8. Go to Step 9.
Check the engine for wear around the piston or
wear of the cylinder liner.

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

Repair or replace the faulty part.

Is the procedure completed? Verify repair. Go to Step 9.
Check for oil decline from the valve stem or oil
seal.

Note:
9 For work procedure, refer to “Engine —
section” in the service manual.

Repair or replace the faulty part.

Is the procedure completed? Verify repair. Go to Step 10.
Overhaul the water pump.

Note:
10 For work procedure, refer to “Engine —
section” in the service manual.

Is the procedure completed? Verify repair. —

Check for oil leakage from the engine external/
internal.
Repair or replace the faulty part.

11 Note: —
For work procedure, refer to “Engine
section” in the service manual.

Is the procedure completed? Verify repair. —

1E-644 Electronic control fuel injection system (Common rail type)

Special Tool
Tool No. Tool No.
Illustration Illustration
Tool name Tool name

5-8840-2691-0
Injector checker
Digital multimeter

IJC

Tech2
Scan tool

5-8840-0632-0
Terminal remover

5-8840-0388-0
Weather pack terminal
remover

5-8840-0385-0
Breaker box

5884003850

Engine module
programming system

EMPS
 Electronic control fuel injection system (Common rail type) 1E-645

Difference by each machine manufacturer

Sumitomo (S.H.I.) Construction Machinery Manufacturing Co., Ltd.

List of DTC Sumitomo ISUZU DTC description Trouble

Sumitomo ISUZU DTC description Trouble (S.H.I.) P Code display
(S.H.I.) P Code display Construction on
Construction on Machinery monitor
Machinery monitor Manufacturing
Manufacturing Co., Ltd.
Co., Ltd. E Code
E Code E0237 P0237 Turbocharger boost
E0340 P0340 Camshaft position sensor circuit low ❍
❍ input
sensor circuit fault
E0340 P0341 Camshaft position E0611 P0611 EDU charge circuit 1
❍ ❍
sensor fault low voltage

E0335 P0335 Crankshaft position E0612 P0612 EDU charge circuit 2

❍ ❍
sensor circuit fault low voltage

E0335 P0336 Crankshaft position E1630 P1630 Analog/digital signal

❍ ❍
sensor fault conversion fault

E1345 P1345 Injection pump — E0234 P0234 High boost fault —

Camshaft positional ❍ E0487 P0487 EGR valve BLDC
correlation fault ❍
position circuit fault
E0113 P0113 Intake air E0488 P0488 EGR valve fault ❍
temperature sensor ❍
circuit high input E0606 P0606 ECM internal trouble
❍
(CPU fault)
E0112 P0112 Intake air
temperature sensor ❍ E1631 P1631 5V #1 circuit fault —
circuit low input E1632 P1632 5V #2 circuit fault ❍
E0118 P0118 Engine coolant E1633 P1633 5V #3 circuit fault ❍
temperature sensor ❍
input is high. E1634 P1634 5V #4 circuit fault ❍

E0117 P0117 Engine coolant E1635 P1635 5V #5 circuit fault ❍

temperature sensor ❍ E1636 P1636 12V circuit fault —
low input
E0236 P0236 Low boost fault —
E1277 P1277 Accelerator sensor 1
— E0380 P0380 Glow relay circuit
low input ❍
fault
E1283 P1283 Accelerator sensor 2
— E0108 P0108 Barometric pressure
high input
sensor circuit high ❍
E1282 P1282 Accelerator sensor 2 input
—
low input
E0107 P0107 Barometric pressure
E1287 P1287 Accelerator sensor 3 sensor circuit low ❍
—
low input input
E1271 P1271 Accelerator sensor 1 E0650 P0650 Check engine
— 2 positional — —
control circuit fault
correlation fault
E2104 U2104 CAN communication
E0238 P0238 Turbocharger boost ❍
fault
sensor circuit high ❍
input
1E-646 Electronic control fuel injection system (Common rail type)

Sumitomo ISUZU DTC description Trouble Sumitomo ISUZU DTC description Trouble
(S.H.I.) P Code display (S.H.I.) P Code display
Construction on Construction on
Machinery monitor Machinery monitor
Manufacturing Manufacturing
Co., Ltd. Co., Ltd.
E Code E Code
E2106 U2106 Communication fault E0201 P0201 No. 1 injector —
❍
with TCM injector circuit fault
❍
(Transmission
E0202 P0202 No. 2 injector —
control module) ❍
injector circuit fault
E0088 P0088 Common rail
E0203 P0203 No. 3 injector —
pressure abnormally ❍
❍ injector circuit fault
high (1st or 2nd
stage) E0204 P0204 No. 4 injector —
❍
injector circuit fault
E0089 P0089 Common rail
pressure fault E0205 P0205 No. 5 injector —
❍
(Excessive pressure ❍ injector circuit fault
feed in supply
E0206 P0206 No. 6 injector —
pump) ❍
injector circuit fault
E1261 P1261 COMMON1
E1625 P1625 Main relay circuit
(Harness or injector ❍
stuck open or stuck ❍
harness)
closed
E1262 P1262 COMMON2
E0522 P0522 Oil pressure circuit
(Harness or injector ❍ ❍
open circuit
harness) circuit fault
E0523 P0523 Oil pressure circuit
E0183 P0183 Fuel temperature ❍
short circuit
sensor circuit high —
input E1113 P1113 Boost temperature
—
sensor open circuit
E0182 P0182 Fuel temperature
sensor circuit low — E1112 P1112 Boost temperature
—
input sensor short circuit
E1095 P1095 Pressure limiter is E0219 P0219 Overrun ❍
❍
operated.
E1173 P1173 Overheat —
E1093 P1093 Fuel leakage (large
❍ E0603 P0603 EEPROM fault ❍
amount)
E0601 P0601 ROM fault ❍
E0087 P0087 Common rail
pressure low E0606 P0606 CPU monitoring IC
❍
pressure fault (No ❍ fault
pressure feed in
supply pump)
E0193 P0193 Common rail
pressure sensor ❍
circuit high input
E0192 P0192 Common rail
pressure sensor ❍
circuit low input
E0090 P0090 Common rail
pressure control
❍
adjusting valve
circuit fault
 Electronic control fuel injection system (Common rail type) 1E-647
List of DTC that vary depending on the machine manufacturer
On some machines, the diagnosis lamp comes on instead of trouble display monitor on the machine.
4HK1
Recovery
Flash DTC Item to be Preconditions when Judgment Behavior when Diagnos
DTC DTC set condition from
code description detected DTC is set Time trouble occurs is lamp
failure
P0192 245 Common rail Short circuit • Key switch input Common rail Nearly Engine blow up ON *2
pressure in sensor or voltage is 18V or pressure sensor simultane Back-up:
sensor fault harness more. voltage is less ous to Rail pressure
(low voltage • DTC P1630 or than 0.7 V. fault feedback control
fault) P1635 is not occurrenc stopped
detected. e Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Switches the
control to SCV
compulsory drive.
P0193 Common rail Open/short • Key switch input Common rail Nearly Engine stall ON *2
pressure circuit/ voltage is 18V or pressure sensor simultane possible
sensor fault breakage of more. voltage is more ous to Output lowering
(high voltage sensor or • DTC P1630 or than 4.5 V. fault Back-up:
fault) harness P1635 is not occurrenc Rail pressure
detected. e feedback control
stopped
Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Switches the
control to SCV
compulsory drive.
P0219 543 Overrun Engine • Key switch input When engine Approx. 1 Output lowering ON *2
speed voltage is 18V or speed is more sec. Back-up:
abnormally more. than 210 rpm. Limited injection
high amount 1
Limitation is lifted if
the speed
decreases
P0237 32 Boost Open/short • Key switch input Boost pressure Approx. 3 Operationality is ON *2
pressure circuit/ voltage is 18V or sensor voltage is sec. affected.
sensor fault breakage of more. less than 0.1V. Back-up:
(low voltage sensor or • DTC P1630 or Boost pressure
fault) harness P1634 is not default setting
detected. (150 kPa {21.8
psi})
Boost pressure
correction/EGR
stopped
P0238 Boost Short circuit • Key switch input Boost pressure Approx. 3 Black smoke ON *2
pressure in sensor or voltage is 18V or sensor voltage is sec. emitted
sensor fault harness more. more than 4.9V. Back-up:
(high voltage • DTC P1630 or Boost pressure
fault) P1634 is not default setting
detected. (150 kPa {21.8
psi})
Boost pressure
correction/EGR
stopped
1E-648 Electronic control fuel injection system (Common rail type)

Recovery
Flash DTC Item to be Preconditions when Judgment Behavior when Diagnos
DTC DTC set condition from
code description detected DTC is set Time trouble occurs is lamp
failure
P1113 295 Boost Short circuit • Key switch input Boost Approx. 4 Operationality is ON *2
temperature in sensor or voltage is 18V or temperature sec. not affected.
sensor fault harness more. sensor voltage is Back-up:
(high voltage • Coolant more than 4.95V. Back-up: No back-
fault) temperature is up action
50°C (122°F) or
more.
• 5 minutes or more
has elapsed after
starting engine.
• DTC P1634 is not
detected.
P1345 16 Cam sensor Camshaft • Key switch input Correct cam When • Behavior does ON *1
out of phase gear/ voltage is 18V or pulse does not trouble not change during
crankshaft more. exist in crank gap occurs 7 engine running.
gear • DTC P0335, position. out of 8 • After engine
installing P0336, P0340, samples. stalls, engine will
angle is out P0341, P1345, or not start.
of phase, or P1635 is not Back-up:
damage in detected. Engine running
gear. • CMP sensor based on crank
pulse is normal. when it is normal
• Crank pulse is After engine stops:
normal. Unable to identify
cylinder (unable to
restart)
U2104 84 CAN Bus CAN • Key switch input Bus-off is At 3 sec. Set to idle speed. ON *3
fault communicati voltage is 20V or detected. continuou Back-up:
on fault more. sly Running at 1500
rpm.
U2106 85 CAN timeout CAN • DTC U2104 is not CAN data At 1 sec. Set to idle speed. ON *3
fault communicati detected. reception does continuou Back-up:
on fault • Key switch input not complete at a sly Running at 1500
voltage is 20V or set time. rpm.
more.

*1, *2, *3: Refer to “About recovery from failure” in “List of diagnostic trouble code”.
 Electronic control fuel injection system (Common rail type) 1E-649
6HK1
Recovery
Flash DTC Item to be Preconditions when Judgment Behavior when Diagnos
DTC DTC set condition from
code description detected DTC is set Time trouble occurs is lamp
failure
P0112 22 Intake air Short circuit • Key switch input Intake air Approx. 4 Not in particular ON *2
temperature in sensor or voltage is 18V or temperature sec. Back-up:
sensor fault harness more. sensor voltage is Intake air
(low voltage • DTC P1630 or less than 0.1 V. temperature default
fault) P1632 is not setting
detected (at starting: −10°C
{14°F}, at running:
25°C {77°F})
EGR stopped
P0117 23 Engine Short circuit • Key switch input Engine coolant Approx. 4 Start ability ON *2
coolant in sensor or voltage is 18V or temperature sec. deteriorates at low
temperature harness more. sensor voltage is temperatures or
sensor fault • DTC P1630 or less than 0.1 V. black smoke
(low voltage P1633 is not emission is
fault) detected. possible, output
lowering
depending on
conditions.
Back-up:
Coolant
temperature default
setting
(at starting: −20°C
{−4°F}, at running:
80°C {176°F)
EGR stopped
P0182 211 Fuel Short circuit • Key switch input Combustion Approx. 4 Operationality is ON *2
temperature in sensor or voltage is 18V or temperature sec. affected.
sensor fault harness more. sensor voltage is Back-up:
(low voltage • DTC P1630 or less than 0.1 V. Fuel temperature
fault) P1633 is not default setting
detected. (at starting: −20°C
{−4°F}, at running:
70°C {158°F)
P0192 245 Common rail Short circuit • Key switch input Common rail Nearly Engine blow up ON *2
pressure in sensor or voltage is 18V or pressure sensor simultane Back-up:
sensor fault harness more. voltage is less ous to Rail pressure
(low voltage • DTC P1630 or than 0.7 V. fault feedback control
fault) P1635 is not occurrenc stopped
detected. e Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Switches the
control to SCV
compulsory drive.
P0193 Common rail Open/short • Key switch input Common rail Nearly Engine stall ON *2
pressure circuit/ voltage is 18V or pressure sensor simultane possible
sensor fault breakage of more. voltage is more ous to Output lowering
(high voltage sensor or • DTC P1630 or than 4.5 V. fault Back-up:
fault) harness P1635 is not occurrenc Rail pressure
detected. e feedback control
stopped
Limited injection
amount 2 (multi-
injection stopped)
EGR stopped
Switches the
control to SCV
compulsory drive.
1E-650 Electronic control fuel injection system (Common rail type)

Recovery
Flash DTC Item to be Preconditions when Judgment Behavior when Diagnos
DTC DTC set condition from
code description detected DTC is set Time trouble occurs is lamp
failure
P0219 543 Overrun Engine • Key switch input When engine Approx. 1 Output lowering ON *2
speed voltage is 18V or speed is more sec. Back-up:
abnormally more. than 2300 rpm. Limited injection
high amount 1
Limitation is lifted if
the speed
decreases
P0380 66 Glow relay Open/short • Key switch input No glow relay When Operationality is ON *1
fault circuit/ power supply monitor signal trouble not affected.
damage of voltage is higher exists against occurs 25 Back-up:
relay or than 16 V but lower glow relay drive out of 30 Back-up: No back-
harness than 32 V. indication. samples. up action
P1113 295 Boost Short circuit • Key switch input Boost Approx. 4 Operationality is ON *2
temperature in sensor or voltage is 18V or temperature sec. not affected.
sensor fault harness more. sensor voltage is Back-up:
(high voltage • Coolant more than 4.95V. Back-up: No back-
fault) temperature is up action
50°C (122°F) or
more, or 3 minutes
or more has
elapsed after
starting engine.
• DTC P1634 is not
detected.
P1345 16 Cam sensor Camshaft • Key switch input Correct cam When • Behavior does ON *1
out of phase gear/ voltage is 18V or pulse does not trouble not change during
crankshaft more. exist in crank gap occurs 7 engine running.
gear • DTC P0335, position. out of 8 • After engine
installing P0336, P0340, samples. stalls, engine will
angle is out P0341, P1345, or not start.
of phase, or P1635 is not Back-up:
damage in detected. Engine running
gear. • CMP sensor based on crank
pulse is normal. when it is normal
• Crank pulse is After engine stops:
normal. Unable to identify
cylinder (unable to
restart)
U2104 84 CAN Bus CAN • Key switch input Bus-off is At 3 sec. Set to idle speed. ON *3
fault communicati voltage is 20V or detected. continuou Back-up:
on fault more. sly Running at 1350
rpm.
U2106 85 CAN timeout CAN • DTC U2104 is not CAN data At 1 sec. Set to idle speed. ON *3
fault communicati detected. reception does continuou Back-up:
on fault • Key switch input not complete at a sly Running at 1350
voltage is 20V or set time. rpm.
more.

*1, *2, *3: Refer to “About recovery from failure” in “List of diagnostic trouble code”.
 Electronic control fuel injection system (Common rail type) 1E-651
Recovery from failure (diagnosis lamp)
After the DTC is detected, the diagnosis lamp comes 1 2 3 4

on during 1 ignition cycle from the state that the DTC Key ON
and back-up mode have restored. switch
and
Enigne
run OFF

ON
Diag
lamp
OFF

ON
Back-up
mode
OFF

TSWG0208

Name
1. DTC is detected.
2. Repair and inspection
3. Recovery to normal in ECU (back-up mode)
4. Diagnosis lamp off

List of items displayed on scan tool

Display item Tech2 display item

Actual engine speed Engine Speed
Target engine speed Desired Idle Speed
Glow signal Glow Relay
Coolant temperature Engine Coolant Temperature
Fuel temperature Fuel Temperature
Engine oil pressure Engine Oil Pressure
Barometric pressure Barometric Pressure
Intake air temperature Intake Air Temperature
Boost pressure MAP Sensor
Boost temperature Boost Temperature
Battery voltage Main Relay Voltage
1E-652 Electronic control fuel injection system (Common rail type)
About wiring diagrams
• There are some sensors which are not connected to the ECM depending on specifications of the machine.
• Check the specifications of the machine, since some sensors input/output to ECM via CAN communication.
The areas with screening indicate that are not connected to the ECM.
4HK1

(15A)*
24
Engine stop switch
47
Idling selector switch 107
29 CKP sensor
Idle up switch 106
30
Idle down switch 108
31
Key switch

Mode map switch 0 80

49 Engine oil
Mode map switch 1 67
(ON)

50 79 pressure sensor
Mode map switch 2
51
84
Diagnostic lamp 6 Engine coolant
Engine oil pressure lamp temperature sensor
(50A)*

17
QOS indicator lamp 11 83
Fuel temperature
Boost temperature lamp 7 sensor
10
(60A)* 99
98 CMP sensor
Glow relay 100
Key switch

87
82
(ST)

90 Common rail
Main relay Glow plug pressure sensor
21 101
40
(10A)*

(30A)*
2 94 U
EGR valve
93 V
5 position sensor
92 W
(100A)*

46

Fuel pump relay Vehicle speed

19
sensor

121
Battery

(10A)*

Fuel pump Injector #1

119
ECM

M
Charge 117 Injector #4
lamp O/H lamp O/H switch

116
Generator
R Injector #3
L 120
Safty relay B terminal
E Sterter 118 Injector #2

R S S terminal SCV
B C B terminal 105
113
89
97
42
Accelerator
position 63 8 Tachometer
sensor 64
41
20 18
Barometric 61 37
pressure 71
sensor 60
Intake air 72
temperature
38 7 TOOL
sensor
52 1
Boost 95 4 Data link connector
pressure 91 5
sensor 109
Boost 74
temperature 81
sensor
43

U 111 62
EGR valve V 103
M 1
motor W 110
3
Memory clear switch
32 4

TSHK0048
 Electronic control fuel injection system (Common rail type) 1E-653
6HK1

(15A)*
24 107 CKP sensor
Engine stop switch 106
47
Diagnostic lamp 6 108
Engine oil pressure lamp
Key switch

17 80
QOS indicator lamp 67 Engine oil
11 pressure sensor
79
(ON)

Boost temperature lamp

7
84 Engine coolant
10
temperature sensor
(50A)*

Glow relay 83 Fuel temperature

sensor

Glow plug 99
(60A)* CMP sensor
98
100
87
Key switch

Main relay
21
82
40 Common rail
(ST)

(30A)* 90
2 101 pressure sensor

5
(10A)*

94 U EGR valve
93 V position sensor
92 W
46
(100A)*

19 Vehicle speed
Fuel pump relay sensor
121

Injector #1
119
Battery

(10A)*

Fuel pump
114 Injector #2
ECM

M
Charge
lamp O/H lamp O/H switch
117 Injector #3

116
Generator
R
L Injector #4
115
Safty relay B terminal
E Sterter Injector #5
120
R S S terminal
B C B terminal Injector #6
118
SCV
105
42 113
Accelerator
position 63 89
sensor 64 97
41
20 8 Tachometer
Barometric 61
pressure 71
sensor 60 18
37
Intake air 72
temperature
sensor
38 7 TOOL
Boost 95
52 1 Data link connector
pressure 91
sensor 109 4
5
Boost 74
temperature 81
sensor
43

U 111 62
EGR valve V 103
M 1
motor W 110
3
Memory clear switch
32 4

TSHK0049
1E-654 Electronic control fuel injection system (Common rail type)
Tech2 reference value
The data list is used to check the conditions of the
machine and each equipment.
Each machine data is compared with standard value.
The data list is used in trouble diagnosis to judge as out
of reference value temporarily or all the time. (This
Tech2 display menu is subject to change without notice.
6HK1 (Idle)

Data display item Units Reference value at idle (it varies depending on
conditions of the machine.)
System Voltage V 22 — 30
Main Relay Voltage V 22 — 30
Desired Idle Speed RPM 500
Engine Speed RPM 895 — 905
Accelerator Sensor 1 V 0.0
Accelerator Sensor 2 V 0.0
Accelerator Pedal Position % 0
Difference in Common Rail Pressure MPa 0±3
Common Rail Pressure Sensor V 1.5
Common Rail Pressure F/B Mode Feedback Mode
SCV Duty % Approx. 25 — 50
SCV F/B mA Approx. 800 — 1,200
Engine Coolant Temperature Sensor V 0.4
Engine Coolant Temperature °C 85
Intake Air Temperature Sensor V 2.4
Intake Air Temperature °C 27
Fuel Temperature Sensor V 1.1
Fuel Temperature °C 50
Barometric Pressure Sensor V Approx. 2
Barometric Pressure kPa Approx. 100
Boost Temperature Sensor V 4.4
Manifold Absolute Pressure kPa Approx. 100
No. 1 Cylinder Fuel Injection Correction mm3/st ± 3 or less
Amount
No. 2 Cylinder Fuel Injection Correction mm3/st ± 3 or less
Amount
No. 3 Cylinder Fuel Injection Correction mm3/st ± 3 or less
Amount
No. 4 Cylinder Fuel Injection Correction mm3/st ± 3 or less
Amount
No. 5 Cylinder Fuel Injection Correction mm3/st ± 3 or less
Amount
No. 6 Cylinder Fuel Injection Correction mm3/st ± 3 or less
Amount
 Electronic control fuel injection system (Common rail type) 1E-655

Data display item Units Reference value at idle (it varies depending on
conditions of the machine.)
Engine Mode Fuel Mode
EGR Position Difference % 0
EGR Motor Duty % 0
EGR Position 1 ON/OFF One of 1, 2, 3 is the reverse polarity.
(e.g. 1=ON, 2=ON, 3=OFF)
EGR Position 2 ON/OFF One of 1, 2, 3 is the reverse polarity.
(e.g. 1=ON, 2=ON, 3=OFF)
EGR Position 3 ON/OFF One of 1, 2, 3 is the reverse polarity.
(e.g. 1=ON, 2=ON, 3=OFF)
Starter Switch (On) ON/OFF ON
Starter Switch (ST) ON/OFF OFF
Idle Manual Switch ON/OFF Auto
Idle Up Switch ON/OFF OFF
Idle Down Switch ON/OFF OFF (ON immediately after key switch ON.)
Glow Relay ON/OFF OFF (ON immediately after key switch ON.)
Glow Lamp ON/OFF OFF
Diagnostic Switch ON/OFF —
Q Adjust Resistance Data 1 — Varies depending on the machine
Q Adjust Resistance Data 2 — Varies depending on the machine
Q Adjust Resistance Data 3 — Varies depending on the machine

6HK1 (Two pump relief)

Data display item Units Reference value for Two pump relief (it varies
depending on conditions of the machine.)
System Voltage V 22 — 30
Main Relay Voltage V 22 — 30
Desired Idle Speed RPM 500
Engine Speed RPM 1,945 — 1,950
Accelerator Sensor 1 V 0.0
Accelerator Sensor 2 V 0.0
Accelerator Pedal Position % 0
Difference in Common Rail Pressure MPa 0±5
Common Rail Pressure Sensor V 1.5
Common Rail Pressure F/B Mode Feedback Mode
SCV Duty % Approx. 15 — 50
SCV F/B mA Approx. 600 — 900
Engine Coolant Temperature Sensor V 0.4 — 0.5
Engine Coolant Temperature °C 80 — 85
Intake Air Temperature Sensor V 2.2
Intake Air Temperature °C 29
1E-656 Electronic control fuel injection system (Common rail type)

Data display item Units Reference value for Two pump relief (it varies
depending on conditions of the machine.)
Fuel Temperature Sensor V 1.0
Fuel Temperature °C 53
Barometric Pressure Sensor V Approx. 2
Barometric Pressure kPa Approx. 100
Boost Temperature Sensor V 4.3
Manifold Absolute Pressure kPa Approx. 180 — 200
No. 1 Cylinder Fuel Injection Correction mm3/st ± 3 or less
Amount
No. 2 Cylinder Fuel Injection Correction mm3/st ± 3 or less
Amount
No. 3 Cylinder Fuel Injection Correction mm3/st ± 3 or less
Amount
No. 4 Cylinder Fuel Injection Correction mm3/st ± 3 or less
Amount
No. 5 Cylinder Fuel Injection Correction mm3/st ± 3 or less
Amount
No. 6 Cylinder Fuel Injection Correction mm3/st ± 3 or less
Amount
Engine Mode Fuel Mode
EGR Position Difference % −20 — 0
EGR Motor Duty % 0 — 97
EGR Position 1 ON/OFF One of 1, 2, 3 is the reverse polarity.
(e.g. 1=ON, 2=ON, 3=OFF)
EGR Position 2 ON/OFF One of 1, 2, 3 is the reverse polarity.
(e.g. 1=ON, 2=ON, 3=OFF)
EGR Position 3 ON/OFF One of 1, 2, 3 is the reverse polarity.
(e.g. 1=ON, 2=ON, 3=OFF)
Starter Switch (On) ON/OFF ON
Starter Switch (ST) ON/OFF OFF
Idle Manual Switch ON/OFF Auto
Idle Up Switch ON/OFF OFF
Idle Down Switch ON/OFF OFF (ON immediately after key switch ON.)
Glow Relay ON/OFF OFF (ON immediately after key switch ON.)
Glow Lamp ON/OFF OFF
Diagnostic Switch ON/OFF —
Q Adjust Resistance Data 1 — Varies depending on the machine
Q Adjust Resistance Data 2 — Varies depending on the machine
Q Adjust Resistance Data 3 — Varies depending on the machine
 Electronic control fuel injection system (Common rail type) 1E-657
Method to identify faulty injector
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.
Measuring period should be 3 to 5 minutes after the engine stabilized. Measure and compare the exhaust pipe
temperature of each cylinder, and judge as faulty cylinder if the temperature of certain cylinder is significantly lower
than others.

Comparing exhaust pipe temperature

The following comparison data is for reference.

Caution:
Be careful that the measurement value can differ from the test value depending on actual test environment
or machine conditions.

In normal condition

400
(752)

300
(572)
C ( F)

200
(392)

100
(212)

0
(32)
TSHK0138
In the normal condition, temperatures of all the cylinders shows similar tendency.

°C (°F)
Test period #1 #2 #3 #4 #5 #6
0 21 (70) 21 (70) 21 (70) 21 (70) 21 (70) 21 (70)
40 51 (124) 55 (131) 55 (131) 55 (131) 54 (129) 84 (183)
1:10 170 (338) 169 (336) 174 (345) 199 (390) 190 (374) 216 (421)
1:40 265 (509) 256 (493) 250 (482) 272 (522) 303 (577) 284 (543)
2:20 304 (579) 324 (615) 302 (576) 334 (633) 325 (617) 317 (603)
2:40 328 (622) 342 (648) 328 (622) 358 (676) 355 (671) 342 (648)
1E-658 Electronic control fuel injection system (Common rail type)
When injection in No. 1 cylinder stops

400
(752)

300
(572)
C ( F)

200
(392)

100
(212) #1

TSHK0139
There are significant difference in the temperature between it and other cylinders that perform normal injection.

°C (°F)
Test period #1 #2 #3 #4 #5 #6
0 56 (133) 60 (140) 66 (151) 65 (149) 62 (144) 62 (144)
35 57 (135) 135 (275) 193 (379) 193 (379) 190 (374) 216 (421)
1:00 61 (142) 165 (329) 246 (475) 255 (491) 322 (612) 276 (529)
1:25 66 (151) 187 (369) 288 (550) 312 (594) 345 (653) 300 (572)
2:00 74 (165) 208 (406) 305 (581) 341 (646) 350 (662) 326 (619)
2:30 77 (171) 217 (423) 332 (630) 345 (653) 368 (694) 341 (646)
3:05 80 (176) 221 (430) 346 (655) 367 (693) 372 (702) 352 (666)

When injection in No. 3 cylinder stops

400
(752)

300
(572)
C ( F)

#3
200
(392)

100
(212)

TSHK0140

The temperature of it keeps lower than normal

cylinders.
 Electronic control fuel injection system (Common rail type) 1E-659

°C (°F)
Test period #1 #2 #3 #4 #5 #6
0 81 (178) 91 (196) 105 (221) 101 (214) 98 (208) 81 (178)
30 127 (261) 180 (356) 128 (262) 245 (473) 257 (495) 247 (477)
1:10 202 (396) 297 (567) 145 (293) 275 (527) 280 (536) 282 (540)
1:40 233 (451) 332 (630) 206 (403) 311 (592) 311 (592) 319 (606)
2:20 263 (505) 367 (693) 206 (403) 342 (648) 323 (613) 337 (639)
2:50 294 (561) 365 (689) 253 (487) 354 (653) 327 (621) 346 (655)
3:25 297 (567) 398 (748) 229 (444) 369 (696) 360 (680) 356 (673)

When injection in No. 6 cylinder stops

300
(572)
C ( F)

200
(392)

100 #6
(212)

TSHK0141

There are significant difference in the temperature between it and other cylinders that perform normal injection.

°C (°F)
Test period #1 #2 #3 #4 #5 #6
0 91 (196) 106 (223) 124 (255) 116 (241) 113 (235) 98 (208)
40 136 (277) 159 (318) 165 (329) 199 (390) 171 (340) 93 (199)
1:10 224 (435) 241 (466) 239 (462) 270 (518) 210 (410) 93 (199)
1:40 252 (486) 295 (563) 288 (550) 304 (579) 231 (448) 91 (196)
2:20 320 (608) 333 (631) 243 (469) 266 (511) 240 (464) 98 (208)
2:40 331 (628) 324 (615) 255 (491) 313 (595) 252 (486) 93 (199)
1E-660 Electronic control fuel injection system (Common rail type)