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TROUBLESHOOTING
ECD (ELECTRONIC CONTROL DIESEL)
SYSTEM........................................................................ 1-2
CAUTIONS ...................................................................... 1-2
FUNCTION INSPECTION ............................................... 1-2
BASIC INSPECTION....................................................... 1-2
PARTS LAYOUT DRAWING ........................................... 1-4
DIAGNOSIS CODE LIST................................................. 1-5
LIST OF SYMPTOMS...................................................... 1-7
DESCRIPTION OF FUNCTION..................................... 1-10
PROCEDURE FOR TROUBLESHOOTING.................. 1-11
INSPECTING/DELETING DIAGNOSIS CODE ............. 1-13
FREEZE FRAME DATA/DIAGNOSIS
DETAILED INFORMATION ........................................ 1-14
INSPECTION OF IRREGULAR PROBLEMS ............... 1-15
WORK SUPPORT ......................................................... 1-16
CIRCUIT DIAGRAM ...................................................... 1-30
ECU TERMINAL LAYOUT ............................................ 1-33
ECU DATA MONITOR/ACTIVE TEST........................... 1-39
FAIL SAFE LIST............................................................ 1-52
INDIVIDUAL INSPECTION ...................................... 1-293
INTAKE AIR FLOW METER S/A INSPECTION ......... 1-294
1KD_RM.book 1 ページ 2013年9月27日 金曜日 午後12時47分
1-2
1KD_RM.book 2 ページ 2013年9月27日 金曜日 午後12時47分
1-2
ECD (ELECTRONIC CONTROL DIESEL) SYSTEM
CAUTIONS
1. Precautions for using the 'Engine Diagnostic Program'
WARNING:
• Read the 'Engine Diagnostic Program' instruction manual before using it.
• In operating the machine with the 'Engine Diagnostic Program' connected, be careful of handling so that
the cable of the 'Engine Diagnostic Program' does not hang on the pedal, the shift lever, or the steering
wheel.
• In operating the machine using the tool (such as performing a simulation test), to avoid operations while
controlling the tool, two operators should always work and observe work rules.
FUNCTION INSPECTION
1. Accelerator position sensor (potentiometer) (See the lift truck repair manual for the procedure.)
2. Intake air flow meter
Caution:
• Follow the procedure below to inspect the intake air flow meter S/A.
• With the engine stopped, when a value of [MAF] from [Data monitor] does not meet the standard or when
foreign matter is found in the platinum filament (heater) portion of the intake air flow meter S/A, the meter
should be replaced.
(1) Intake air quantity inspection
SST 09111-36760-71 (09991-70201)
Caution:
• With the engine stopped, keep the machine horizontal and inspect these functions indoors.
• Perform inspection with the intake air flow meter S/A mounted on the intake pipe (with the machine
installed).
• Do not suck air from the exhaust tail pipe in the exhaust duct.
(a) Turn the ignition key switch on and wait for 30 seconds.
(with the engine stopped)
(b) According to the instruction of the 'Engine Diagnostic Program' screen, press [Data monitor] and monitor
[MAF] and read a numerical value.
Reference 1.2 g/sec (0.16 lb/min) or less
(2) Sensor foreign matter adhesion inspection
(a) Visually check the platinum filament (heater) portion in flow paths.
Standard No foreign matter that can be visually checked
Note:
After checking that no foreign matter is found, return the intake air flow meter S/A to the machine.
BASIC INSPECTION
Note:
When the location of a defect cannot be identified even after troubleshooting, it can be pinpointed through
the basic inspection below.
1. Battery inspection (See the machine repair manual for the procedure.)
2. Cranking operation inspection
(1) Inspect if the engine cranks.
Note:
If it does not crank, inspect relevant portions, referring to the LIST OF SYMPTOMS
(See page 1-7 for the procedure.)
1KD_RM.book 2 ページ 2013年9月27日 金曜日 午後12時47分
1-3
3. Engine start inspection
(1) Inspect if the engine starts.
NOTICE:
• Engine should be cranked by two rotations at minimum when engine starting because ECD system
electrically detects the fuel injected cylinder.
• If it does not start, inspect relevant portions, referring to the LIST OF
SYMPTOMS (See page 1-8 for the procedure.)
4. Air filter inspection (See the machine repair manual for the procedure.)
5. Idle speed inspection
(1) Inspect idling.
Reference: Refer to repair manual of the vehicle (after warm-up, during idling)
6. Fuel pressure inspection
SST: 09240-36770-71
(1) According to the instruction of the screen, press [Data monitor] and monitor [Fuel Press] and measure fuel
pressure.
Reference: 30000 to 50000 kPa (after warm-up, during idling)
7. Fuel property
Inspect if a proper fuel is used as described in the Operator's Manual.
Diesel fuel
For 8FD35U to 8FD80U model
Use only ultra low-sulfur fuel defined by ASTM D0975 No.2-D S15.
Refer to the following table for details.
Detailed Requirement for ASTM D0975 No.2-D S15
Property Unit Value
Distillation Temperature °C 90 % 282 to 338
Kinematic Viscosity mm2/s at 40 °C 1.9 to 4.1
Sulfur ppm (μ g/g) max 15
Cetane index -, min 40
Aromaticity %vol, max 35
Lubricity, HFRR μm, max 520
NOTICE:
• Do not use bio-diesel fuel. Damage to engine will occur.
• In cold weather, use winter diesel fuel to prevent clogging of the fuel filter caused by paraffin precipitation.
In hot weather, do not use winter diesel fuel. Damage to engine will occur.
• Do not use deteriorated fuel which has been stored for a long period of time or impure fuel in which
foreign material, water and etc. is included.
• If fuel is frozen or becomes wax-like substance in winter season, engine may be hard starting, rough idle
after starting or engine rotation is impossible to increase. In that case, fuel for winter use should be used.
Melt the wax generated in the fuel filter by warming.
1-4
PARTS LAYOUT DRAWING
Fuel pressure sensor
Diesel turbo
pressure sensor
Common rail ASSY
Intake air flow meter
Glow plug ASSY
Injector ASSY
Water temperature sensor
Inlet air
temperature sensor
Crank position
sensor No. 2
Electric EGR
control valve
Oil pressure
switch ASSY
Crank position sensor
Turbo charger S/A
Suction control valve ASSY
Fuel temperature
sensor
Pressure limiter
1KD_RM.book 4 ページ 2013年9月27日 金曜日 午後12時47分
1-5
DIAGNOSIS CODE LIST
ECD System
Diagnosis code Diagnosis item Lamp on Code stored
Page for
reference
P0046
Turbocharger boost control circuit
range / performance
  1-54
P0047 Turbocharger boost control solenoid circuit low   1-54
P0048 Turbocharger boost control solenoid circuit high   1-54
P007C Charge air cooler temperature sensor circuit low   1-59
P007D Charge air cooler temperature sensor circuit high   1-59
P0087 Fuel rail / system pressure - too low   1-65
P0088 Fuel rail / system pressure - too high   1-72
P0093 Fuel system leak detected - large leak   1-79
P0102 Mass air flow sensor circuit low   1-92
P0103 Mass air flow sensor circuit high   1-92
P0107 Manifold absolute pressure sensor circuit low   1-97
P0108 Manifold absolute pressure sensor circuit high   1-97
P0112 Intake air temperature sensor circuit Low   1-102
P0113 Intake air temperature sensor circuit high   1-102
P0115 Engine coolant temperature sensor circuit   1-108
P0117 Engine coolant temperature sensor circuit low   1-108
P0118 Engine coolant temperature sensor circuit high   1-108
P0180 Fuel temperature sensor "A" circuit   1-113
P0182 Fuel temperature sensor "A" circuit low   1-113
P0183 Fuel temperature sensor "A" circuit high   1-113
P0190 Fuel rail pressure sensor circuit   1-65
P0192 Fuel rail pressure sensor circuit low   1-65
P0193 Fuel rail pressure sensor circuit high   1-65
P0201 Injector circuit / open - (Cylinder 1)   1-118
P0202 Injector circuit / open - (Cylinder 2)   1-118
P0203 Injector circuit / open - (Cylinder 3)   1-118
P0204 Injector circuit / open - (Cylinder 4)   1-118
P0299 Turbocharger underboost   1-131
P0335 Crankshaft position sensor circuit   1-133
P0339 Crankshaft position sensor circuit intermittent ×  1-133
P0340 Camshaft position sensor circuit   1-137
P0405 Exhaust gas recirculation sensor circuit low   1-141
P0406 Exhaust gas recirculation sensor circuit high   1-141
P042E Exhaust gas recirculation control stuck open   1-146
P0489 Exhaust gas recirculation control circuit low   1-151
P0490 Exhaust gas recirculation control circuit high   1-151
P0560 System voltage   1-154
P0606 ECM / PCM processor   1-157
P060A
Internal control module monitoring processor
performance
  1-157
P060B
Internal control module A/D processing
performance
  1-157
P0617 Starter relay circuit high   1-159
1KD_RM.book 5 ページ 2013年9月27日 金曜日 午後12時47分
1-6
P0627 Fuel pump control circuit / open   1-162
P062D Fuel injector driver circuit performance   1-118
P062F Internal control module EEPROM error   1-166
P1229 Fuel pump system   1-169
P1251
Motor for turbocharger control circuit
(Intermittent)
  1-173
P2120 Pedal position sensor "D" circuit   1-180
P2121
Pedal position sensor "D" circuit
range / performance
  1-188
P2122 Pedal position sensor "D" circuit low   1-180
P2123 Pedal position sensor "D" circuit high   1-180
P2125 Pedal position sensor "E" circuit   1-180
P2127 Pedal position sensor "E" circuit low   1-180
P2128 Pedal position sensor "E" circuit high   1-180
P2138 Pedal position sensor "D" / "E" voltage correlation   1-180
P2226 Barometric pressure circuit   1-191
P2228 Barometric pressure circuit low   1-191
P2229 Barometric pressure circuit high   1-191
P2564
Turbocharger boost control position sensor
"A" circuit low
  1-193
P2565
Turbocharger boost control position sensor
"A" circuit high
  1-193
U0101 Lost communication with can ×  1-197
Diagnosis code Diagnosis item Lamp on Code stored
Page for
reference
1KD_RM.book 6 ページ 2013年9月27日 金曜日 午後12時47分
1-7
LIST OF SYMPTOMS
ECD System
Symptom Portion to be inspected
Page for
reference
Does not crank
Battery -
Starter 5-2
Starting relay -
Shift lever position -
Fast idling rough
Fuel filter -
Injector ASSY 1-118
Starter system 1-199
Engine control computer -
Suction control valve ASSY 1-296
Fuel pressure sensor 1-296
Intake air flow meter 1-294
Fuel property 1-3
Water temperature sensor 1-295
Fuel piping
(blocking from the tank to the supply pump)
-
Idle speed high
Troubleshooting of rough idle and large vibration 1-270
Injector ASSY 1-118
Starter system 1-199
Engine control computer -
Suction control valve ASSY 1-296
Fuel pressure sensor 1-296
Water temperature sensor 1-295
Accelerator position sensor (potentiometer) -
Idle speed low
Troubleshooting of rough idle and large vibration 1-270
Injector ASSY 1-118
Electric EGR control valve 1-296
Compression 2-79
Valve clearance 2-78
Fuel piping -
Engine control computer -
Suction control valve ASSY 1-296
Fuel pressure sensor 1-296
Idle unstable
Troubleshooting of rough idle and large vibration 1-270
Injector ASSY 1-118
Fuel piping -
Electric EGR control valve 1-296
Compression 2-79
Valve clearance 2-78
Engine control computer -
Suction control valve ASSY 1-296
Fuel pressure sensor 1-296
Fuel property 1-3
Power steering system -
Alternator ASSY (external accessory) 7-4
1KD_RM.book 7 ページ 2013年9月27日 金曜日 午後12時47分
1-8
Hunting
Injector ASSY 1-118
ECU power supply system 1-290
Compression 2-79
Fuel piping -
Valve clearance 2-78
Engine control computer -
Suction control valve ASSY 1-296
Fuel pressure sensor 1-296
Fuel property 1-3
Power steering system -
Alternator ASSY (external accessory) 7-4
White smoke is discharged
Electric EGR control valve 1-296
Injector ASSY 1-118
Fuel filter -
Engine control computer -
Suction control valve ASSY 1-296
Fuel pressure sensor 1-296
Preheating control circuit system 1-206
Fuel property 1-3
Compression 2-79
Turbo charger oil leak and white smoke 1-234
White smoke 1-224
Black smoke is discharged
Troubleshooting of black smoke 1-249
Electric EGR control valve 1-296
Injector ASSY 1-118
Exhaust system clogging -
Hard starting, engine stalling
Troubleshooting of hard starting and engine stalling 1-212
Starter system 1-199
Preheating control circuit system 1-206
Fuel property 1-3
ECU power supply system 1-290
VC power supply system 1-284
Battery -
Lack of power, hesitation, surge
(hesitation)
Troubleshooting of lack of power, hesitation, and surge (hesi-
tation)
1-260
Rough idling, large vibration
Troubleshooting of rough idle and large vibration 1-270
ID code writing abnormality 1-16
Knocking, abnormal noise
Troubleshooting of knocking and abnormal noise 1-277
Turbo charger S/A noise 1-243
Symptom Portion to be inspected
Page for
reference
1KD_RM.book 8 ページ 2013年9月27日 金曜日 午後12時47分
1-9
Abnormal engine noise, or noisy engine
Note:
It is not abnormal phenomenon engine noise becomes higher when engine revolution is decreased to idle
state after engine revolution increased higher. And this noise tend to become higher at low temperature, but
it is not abnormal phenomenon.
Engine status where
noise is often heard
Example of
sound
Probable cause NOTE:
During idling
Rasping sound
Water pump bearing
defect
Put a sound scope on the water pump
body to check.
• Remove the V-ribbed belt and try to
rotate by hand. If the turning feels
rough or bumpy to the hand, then the
bearing is defective.
Squealing sound
Squeaking
sound
Oil seal squeal
Apply engine oil from outside the seal,
or spray an anti-squealing agent.
• The sound gets smaller or stops.
Hissing noise Air suction sound
Inspect the intake manifold and air
cleaner for appropriate installation.
• Try plugging the place where the air
gets in with engine oil, grease or
cloth.
Certain engine speed
Squealing sound Belt slipping
The sound occurs on sudden accelera-
tion from idle.
• Check if the indicator mark of the V-
ribbed belt tensioner ASSY is in the
range of the standard value.
(See page 2-77 for the procedure.)
• Inspect the V-ribbed belt for wear,
cracks and adhered oil.
Knocking sound
Piston side knock
Heard from the lower part of the
engine.
Knocking sound of the
connecting rod bearing
Knocking sound of the
crankshaft bearing
Piston pin knocking
sound
Whistling sound Turbo charger S/A
Sound volume and pitch are propor-
tional to the turbo charger S/A or
engine speed.
Whole engine speed
Clicking sound
Clattering sound
Excess valve clearance
or faulty contact
Adjust the valve clearance.
(See page 2-77 for the procedure.)
A "raspberry"
sound
A "put-put"
sound
Exhaust leak
Check by blocking with a wet cloth the
likely location of the leak in the
exhaust system.
• The noise becomes louder when the
engine speed is increased.
1KD_RM.book 9 ページ 2013年9月27日 金曜日 午後12時47分
1-10
Excessive engine oil consumption
DESCRIPTION OF FUNCTION
1. What is the ID code (compensation code)?
(1) For the optional injection characteristic of the injector
ASSY, the engine control computer performs different
injection period compensation for each injector ASSY.
This compensation data is punched as a 30-digit
alphanumeric ID code on the head of the injector ASSY.
The ID code should be written when the injector ASSY or
the engine control computer is replaced.
(See page 1-16 for the procedure.)
Caution:
Improper writing of the ID code can cause rough idling or
abnormal noise.
Cause Inspection or adjustment areas NOTE:
Leaking to the exterior of the
engine
PCV
Engine unit
Turbo charger S/A (See page 1-234 for the procedure)
Leaking to the interior of the
engine
Cylinder head S/A
Cylinder block S/A
Head gasket
Oil loss via the piston ring
A lot carbon build-up will be visible around
the top of the piston.
Oil loss via the valve guide
Determined by the condition of the carbon
adhered to the intake valve cap and the top
of the piston, and by the wetness of the
valve cap caused by oil.
Turbo charger S/A (See page 1-234 for the procedure)
Injector ASSY
ID code
Order in which the ID code
is read or written
No.1 cylinder
No.2 cylinder
No.3 cylinder
No.4 cylinder
1KD_RM.book 10 ページ 2013年9月27日 金曜日 午後12時47分
1-11
PROCEDURE FOR TROUBLESHOOTING
Next
1. Check diagnosis codes and freeze frame data (See page 1-14
for the procedure.)
2. Delete diagnosis codes and freeze frame data (See page 1-13
for the procedure.)
3. Check diagnosis codes again
(See page 1-13 for the procedure.)
Result
A
1. Check the list of diagnosis codes
(See page 1-5 for the procedure.)
Result
1. Check the list of symptoms
(See page 1-7 for the procedure.)
Result
B
1 Making diagnosis and checking symptoms (See page 6-12 for the procedure.)
2 Checking diagnosis codes
Result Go to
A code was output. A
A code was not output. B
B Go to step 4.
3 List of diagnosis codes (main inspection portions) or troubleshooting for each code
Result Go to
A faulty section was identified. A
A faulty section was not identified. B
A Go to step 9.
B Go to step 6.
4 List of symptoms
Result Go to
A faulty section was identified. A
A faulty section was not identified. B
A Go to step 9.
1KD_RM.book 11 ページ 2013年9月27日 金曜日 午後12時47分
1-12
Result
B
1. Perform [Data monitor] and [Active test]
Result
B
Next
Next
Next
Next
5 Basic inspection (See page 1-2 for the procedure.)
Result Go to
A faulty section was identified. A
A faulty section was not identified. B
A Go to step 9.
6 Inspecting with 'Engine Diagnostic Program'
Result Go to
A faulty section was identified. A
A faulty section was not identified. B
A Go to step 9.
7
Inspecting ECU terminal voltage and circuits
(See page 1-33 for the procedure.)
8 INSPECTION OF IRREGULAR PROBLEMS (See page 1-15 for the procedure)
9 Repairing defective parts
10 Checking diagnosis codes (See page 1-5 for the procedure.)
End
1KD_RM.book 12 ページ 2013年9月27日 金曜日 午後12時47分
1-13
INSPECTING/DELETING DIAGNOSIS CODE
Note:
• Read the 'Engine Diagnostic Program' instruction manual before using it.
• 'Engine Diagnostic Program' enables you to select not only the normal mode but the check mode. In the
check mode, abnormality detection sensitivity can be improved, compared to the normal mode.
• Perform inspection in the check mode when normal codes are output in the normal mode despite of
possible abnormalities in a signal system of each sensor.
1. Preparation before inspection
(1) Put the shift position to N.
(2) Disable all of outside loads.
2. Inspecting diagnosis codes (reading with 'Engine Diagnostic Program')
(1) To Use check mode, according to the instruction of the 'Engine Diagnostic Program', press [Utility]  select
[Check mode].
(2) According to the instruction of the 'Engine Diagnostic Program' screen, press [Trouble code] and check the
diagnosis code.
3. Deleting diagnosis code memory (using 'Engine Diagnostic Program')
(1) According to the instruction of the 'Engine Diagnostic Program' screen, press [Trouble code]  press
[Clear], to delete the diagnosis code.
SST 09111-36760-71 (09991-70201)
Caution:
• If it cannot be deleted, turn the ignition key switch OFF and then delete it again.
• Do not delete diagnosis codes with 'Engine Diagnostic Program' before making diagnosis and checking
symptoms.
4. Deleting diagnosis codes (by removing fuse)
(1) Remove the EFI2 fuse (10 A), and in 15 seconds or more
connect the fuse.
Caution:
• Be sure to delete diagnosis code memory after inspecting
and repairing the ECD system. Then, check that normal
codes are output.
• Do not delete diagnosis codes by clearing the battery
(removing the fuse) before making diagnosis and checking
symptoms.
5. Checking diagnosis results (using 'Engine Diagnostic Program')
SST 09111-36760-71 (09991-70201)
Note:
After repairing the faulty system with the output diagnosis code or when performing a recreation test after
deleting the diagnosis code, check output diagnosis codes.
(1) Use 'Engine Diagnostic Program' to delete the diagnosis code.
(2) Perform a test for checking diagnosis results.
(3) According to the instruction of the 'Engine Diagnostic Program' screen, press [Trouble code].
(4) Check diagnosis code results.
1
2
Engine room relay block
EFI2 fuse
1KD_RM.book 13 ページ 2013年9月27日 金曜日 午後12時47分
1-14
FREEZE FRAME DATA/DIAGNOSIS DETAILED INFORMATION
1. Checking freeze frame data (reading with 'Engine Diagnostic Program')
With 'Engine Diagnostic Program', according to the instruction of the screen, press [Trouble code].
Indicates existance of freeze frame data with a mark in [FED], press the mark.
SST 09111-36760-71 (09991-70201)
(1) Turn the ignition key switch ON.
(2) Press [Trouble code].
Indicates existance of freeze frame data with a mark in [FED], press the mark.
(3) In the screen displaying the diagnosis code, detected diagnosis codes appear.
(4) Select a diagnosis code for which freeze frame data is checked.
2. Checking chronological freeze frame data
(1) In the screen displaying freeze data, select an item for
which chronological freeze frame data is checked.
Note:
• Chronological freeze frame data also includes ECU data
recorded at the occurrence of a diagnosis code and around
that point.
• Chronological freeze frame data can be checked when
press a mark in [FED], ' '.
• For chronological freeze frame data, a total number of five
points (including a diagnosis detection point, three points
before detection, one point after detection) can be
displayed.
3. List of freeze frame data
DTC detection point
Freeze frame data recording point
0.5 sec. 0.5 sec. 0.5 sec.
1 2 3 4
Item name
Engine Speed Actual VN Position
Calculate Load VN Position Sensor Out
MAF VN Motor Duty
Atmosphere Pressure VN Close Learn Value
MAP VN Close Learn Status
Coolant Temp Initial Engine Coolant Temp
Intake Air Initial Intake Air Temp
Engine Run Time Engine Start Time
Starter Signal Engine Speed (Starter Off)
Injection Volume Starter Count
Pilot 1 Injection Period Electric Duty Feedback Value
Pilot 2 Injection Period Intake Air Temp (Turbo)
Main Injection Period Battery Voltage
After Injection Period Engine Speed of Cyl #1
Pilot 1 Injection Timing Engine Speed of Cyl #2
Pilot 2 Injection Timing Engine Speed of Cyl #3
Main Injection Timing Engine Speed of Cyl #4
After Injection Timing Av Engine Speed of All Cyl
1KD_RM.book 14 ページ 2013年9月27日 金曜日 午後12時47分
1-15
INSPECTION OF IRREGULAR PROBLEMS
1. Inspecting irregular problems (this can be done only when 'Engine Diagnostic Program' is used)
Note:
Follow the procedure below to change the mode. This allows improvement of disconnection detection
sensitivity and more reliable detection of irregular defects.
(1) Delete diagnosis codes. (See page 1-13 for the procedure and notes.)
(2) Set the check mode. (See page 1-13 for the procedure and notes.)
(3) Perform a simulation (recreation) test. (See page 0-16 for the procedure and notes.)
(4) Visually inspect the connector and each terminal, and inspect the connection condition. (See page 0-11 for
the procedure and notes.)
(5) Inspect the wire harness and connector for excessive force.
(See page 0-13 for the procedure and notes.)
(6) Use a cooling method for inspection. (See page 0-16 for the procedure and notes.)
2. Checking wire harness and connector instantaneous interruption
Note:
If a defective system is found based on an output diagnosis code at the inspection of diagnosis codes
(check mode), its location should be pinpointed in the following way:
(1) After reading the diagnosis code in the check mode, delete diagnosis code memory.
(See page 1-13 for the procedure and notes.)
(2) Select the check mode, and start the engine. (See page 1-13 for the procedure and notes.)
(3) With the engine idling, shake the wire harness and the connector of the defective system where the
diagnosis code was output at the inspection of diagnosis codes (check mode). (See page 0-16 for the
procedure and notes.)
(4) After the wire harness and the connector are shaken, when the engine check indicator turns on, the
connection of them may be poor.
Injector Memory Error Time after DTC Cleared
Target Common Rail Pressure Warmup Cycle Cleared DTC
Fuel Press TC and TE1
Fuel Temperature Isochronous Control Target Speed
Target Pump SCV Current Isochronous Control Proportional Term
Pump SCV Learning Value Isochronous Control Integral Term
Accel Position Total Operation Hours
Accel Sens. No.1 Volt % Total Number of Rotations
Accel Sens. No.2 Volt % Total Injection Volume
Target EGR Pos. Pre Glow
Actual EGR Valve Pos. After Glow
EGR Close Lrn. Val. Target Idle Engine Speed
EGR Close Lrn. Status Adjustment Volume Mode Status Value
after Confirmation
EGR Operation Prohibit
Target Booster Pressure Fuel Return Temp
VN Turbo Command EGR Motor Duty #1
Item name
1KD_RM.book 15 ページ 2013年9月27日 金曜日 午後12時47分
1-16
WORK SUPPORT
1. List of work support steps
When parts requiring initialization and writing have been replaced, initialize and write them by following the steps in
the list below in numerical order.
Note:
The ID code represents 'Engine Diagnostic Program' saved in the engine control computer (injector
compensation code).
2. Initializing the supply pump ASSY learned value
Caution:
Be sure to perform this precedure (initialization) after replacing the pump ASSY or the engine control
computer.
Note:
If an error occurs during the initialization, do it again from <Procedure 1/4>.
Work support item
Replacement
Reading and Saving the
injector compensation code
Initializing the supply
pump ASSY leaned value
Writing the injector
compensation code
Supply pump ASSY (1)
Engine ASSY (1)
Injector ASSY (1)
Supply pump ASSY +
engine ECU
(1) (2) (3)
Injector ASSY +
engine ECU
(1) (2) (3)
Engine ASSY +
engine ECU
(1) (2) (3)
Engine ECU
(with old data)
(1) (2) (3)
Engine ECU
(without old data)
(1) (2)
<Procedure 1/4>
Select [Supply Pump Initialization]
Initialization
Cancel
<Procedure 2/4>
Press [Next] to proceed
<Procedure 3/4>
Check the initial conditions, then press [Next]
<Procedure 4/4>
Supply Pump Initialization is complete, press [Exit]
1KD_RM.book 16 ページ 2013年9月27日 金曜日 午後12時47分
1-17
(1) Turn the ignition key switch ON.
According to the instruction of the 'Engine Diagnostic
Program', press [Utility].
Caution:
Do not start the engine.
(2) <Procedure 1/4>
Select [Supplt Pump Initialization], then press [Select].
(3) <Procedure 2/4>
Press [Next] to proceed.
(4) <Procedure 3/4>
After check the initial conditions, then press [Next].
Caution:
Preform this procedure, the ignition key switch turned on and
the engine stopped.
1KD_RM.book 17 ページ 2013年9月27日 金曜日 午後12時47分
1-18
(5) <Procedure 4/4>
Supply Pump Initialization is complete, press [Exit].
(6) Start up the engine for warm up.
Caution:
Do not perform racing immediately after the engine is started.
Note:
• If the Engine does not start, do it again <procedure 1/4>.
• The engine warm-up state shall be acondition water temperature is 60 °C (140 °F) or more and fuel
temperature is 20 °C (68 °F) or more.
(a) To check water temperature, in the 'Engine Diagnostic Program' select [Data monitor] and monitor
[Coolant Temp]
Reference 60 °C (140 °F) or more
(b) To check fuel temperature, in the 'Engine Diagnostic Program' Select [Data monitor] and monitor [Fuel
Temperature]
Reference 20 °C (68 °F) or more
• When fuel temperature does not increase due toan environment to be measured, increase engine speed
litlle by little until it reaches NMR (No load Maximum Revolution), make it the steady state, and then
increase the temperature. Do not perform racing rapidly.
(7) Run at idle for one minute or more in the state after engine warm-up.
(8) The initializatin is now completed.
1KD_RM.book 18 ページ 2013年9月27日 金曜日 午後12時47分
1-19
3. Reading and Saving the injector compensation code
In this procedure, read codes (injector compensation codes) from the engine control computer, and save compensation
codes to the 'Engine Diagnostic Program'.
Note:
• Due to the defective engine control computer or wire harness, or poor connection of the diagnostic
connector, a writing abnormally may occur. Inspect and check the connection of the wire harness or the
diagnostic connector. When they are normal, the engine control computer may be defective.
• For replacement ECU, need to write the compensation codes of each cylinder. Use this saving
compensation codes function to avoid error, writing incorrect compensation code, install another cylinder
No.
• This saving function can save one latest data of each cylinder.
• If using saved data, confirm the saved compensation code and cylinder number, and compensation code
of the top of the injector ASSY are right.
<Procedure 1/6>
Select [Injector compensation]
Cancel
Read Compensation Code
In case of reading
another cylinder compensation code
Save Replace
<Procedure 2/6>
<Procedure 3/6>
Select a function [Read Compensation Code]
<Procedure 4/6>
Select a Cylinder number
<Procedure 5/6>
Appears Cylinder No and Compensation Code
<Procedure 6/6>
Press [Replace] or [Save]
(In case of there is no
compensation code)
(In case of there is
previous compensation code)
Next
1KD_RM.book 19 ページ 2013年9月27日 金曜日 午後12時47分
1-20
(1) Turn the ignition key switch ON.
According to the instruction of the 'Engine Diagnostic
Program', press [Utility].
Caution:
Do not start the engine.
(2) <Procedure 1/6>
Select [Injector Compensation], then press [Select].
(3) <Procedure 2/6>
Press [Next] to proceed, read <NOTICE> message, then press [Next].
(4) <Procedure 3/6>
Select a function [Read Compensation Code], then press
[Next].
1KD_RM.book 20 ページ 2013年9月27日 金曜日 午後12時47分
1-21
(5) <Procedure 4/6>
Select a Cylinder number from No.1 to 4, then press
[Next].
(6) <Procedure 5/6>
Note:
Appears selected cylinder No. and compensation code.
To save the compensation code, press [Save].
If there is previous saved data, and need to save new compensation data, press [Replace].
If there is no previous saved data, and need to save new
compensation data, press [Save].
Caution:
This saving function can save one latest data of each cylinder.
Confirm the cylinder number, and saved date and time to use
this saved data, in case of writing a compensation code to
replaced engine control computer.
If you need all cylinder compensation codes, repeat this
procedure same times as cilynder numbers.
1KD_RM.book 21 ページ 2013年9月27日 金曜日 午後12時47分
1-22
(7) <Procedure 6/6>
To read another Cylinder’s injector compensation code, press [Next] and repeat this procedure from
<Procedure 4/6>.
To exit this function, press [Cancel].
1KD_RM.book 22 ページ 2013年9月27日 金曜日 午後12時47分
1-23
4. Writing the injector compensation code
In this procedure, write codes (injector compensation codes) to the engine control computer.
• Use saved compensation codes in the 'Engine Diagnostic Program'.
• Input manual compensation codes.
Note:
• Due to the defective engine control computer or wire harness, or poor connection of the diagnostic
connector, a writing abnormally may occur. Inspect and check the connection of the wire harness or the
diagnostic connector. When they are normal, the engine control computer may be defective.
• In case of replacement ECU, need to write the compensation codes of each cylinder. Use saved codes or
input manually.
If using saved data, confirm the saved compensation code and cylinder number, and compensation
code of the top of the injector ASSY are right.
Program can save one latest data of each cylinder.
• In case of replacement ECU, injector ASSY, or engine, need to write the compensation codes of each
cylinder. Input the compensation codes manually.
Confirm the cylinder number and compensation code of the top of the injector ASSY are right.
<Procedure 1/6>
Select [Injector compensation]
Cancel
Replacement
1)engine control computer
Use saved
compensation codes
Input manual
compensation codes
<Procedure 2/6>
<Procedure 3/6>
Select a function [Set Compensation Code]
<Procedure 4/6>
Select a Cylinder number
<Procedure 5-a/6>
Press [Open]
<Procedure 6/6>
Writing is complete
Writing
compensation codes
<Procedure 5-b/6>
Press [Input]
Writing
compensation codes
Replacement
1)engine control computer
2)injector ASSY
3)engine
1KD_RM.book 23 ページ 2013年9月27日 金曜日 午後12時47分
1-24
Note:
If you use the directly read the compensation code, read the
code (30-digit alphanumerical characters) punched on the
head of the injector ASSY.
(1) Turn the ignition key switch ON.
According to the instruction of the 'Engine Diagnostic
Program', press [Utility].
Caution:
Do not start the engine.
(2) Select [Supplt Pump Initialization], then press [Select].
(3) <Procedure 1/6>
Select [Injector Compensation], then press [Select].
(4) <Procedure 2/6>
Press [Next] to proceed, read <NOTICE> message, then press [Next].

Code
Injector ASSY
1KD_RM.book 24 ページ 2013年9月27日 金曜日 午後12時47分
1-25
(5) <Procedure 3/6>
Select a function [Set Compensation Code], then press
[Next].
(6) <Procedure 4/6>
Select a Cylinder number from No.1 to 4, then press
[Next].
Use a saved compensation code: go to (8)
Input a manual compensation code: go to (9)
(7) <Procedure 5-a/6>
Use a saved compensation code, press [Open]  Confirm [Cylinder Number] and [Saved Date], then press
[Open]  press [Next] to write the saved data.
Caution:
Confirm the saved compensation code, cylinder number, and compensation code of the top of the injector
ASSY are right.
Program can save one latest data of each cylinder.
If the compensation code writing error occurs, write again.
 go to (9)
1KD_RM.book 25 ページ 2013年9月27日 金曜日 午後12時47分
1-26
(8) <Procedure 5-b/6>
Input a manual compensation code, press [Input]  Using a key to input the code, then press [OK]  press
[Next] to write the data.
Caution:
Confirm the cylinder number, compensation code of the top of the injector ASSY, input compensation code
are right.
If the compensation code writing error occurs, write again.
If the inputted code is incorrect, 'Error Injector Compensation' occurs, input compensation code correctly.
 go to (9)
(9) <Procedure 6/6>
Injector compensation writing is complete.
Press [Next] to continue writing code of the other cylinder,
press [Cancel] to exit this function.
(10) After completing writing, delete the diagnosis code.
1KD_RM.book 26 ページ 2013年9月27日 金曜日 午後12時47分
1-27
5. Fuel System inspection
Perform this procedure, to air bleeding after fuel system parts replacement, or to check fuel system malfunction.
Note:
• Engine revolution rises, confirm the vehicle not moving.
• Operate acceleration pedal according to the 'Engine Diagnostic Program' screen.
<Procedure 1/8>
Select [Fuel System Check]
Cancel
<Procedure 2/8>
Start the engine
<Procedure 3/8>
Warm up the engine
<Procedure 4/8>
Rise the engine revolution over 1400rpm
<Procedure 5/8>
Check completed
<Procedure 6/8>
Save data (in case of fuel system malfunction check)
<Procedure 7/8>
Repeat 5 times the procedure
<Procedure 8-a/8>
Keep Idling
<Procedure 8-b/8>
Data analysis
Checking the Fuel System
Fuel system parts replacement Fuel system malfunction check
1KD_RM.book 27 ページ 2013年9月27日 金曜日 午後12時47分
1-28
(1) Turn the ignition key switch ON.
According to the instruction of 'Engine Diagnostic
Program', press [Utility].
(2) <Procedure 1/8>
Select [Fuel System Check], then press [Select]
Until the water temperature becomes 70degC (158degF) or higher, can not proceed.
(3) <Procedure 2/8>
Read the message, and start the engine, keep idling, then
press [Next]
(4) <Procedure 3/8>
Warm up the engine.
The water temperature (engine coolant temperature) is
70 °C (158 °F) or higher, then press [Next].
Note:
Until the water temperature becomes 70 °C (158 °F) or higher,
can not proceed.
1KD_RM.book 28 ページ 2013年9月27日 金曜日 午後12時47分
1-29
(5) <Procedure 4/8>
Open the acceleration pedal, rise the engine revolution
over 1400rpm, then press [Next].
Fuel system check starts automatically, needs 15sec,
check is completed.
Caution:
Open the acceleration pedal until the check is completed.
Note:
Fuel system check can proceed under the condition that the
engine revolution is over 1400rpm.
If the condition is not satisfied, the check stops.
The engine revolution automatically keep 1400rpm while the
check is proceeding.
The combustion noise becomes louder while the check is
proceeding, this phenomena is not malfunction.
(6) <Procedure 5/8>
Fuel System Check is completed, close the acceleration
pedal, press [Exit].
(7) <Procedure 6/8>
In case of fuel system malfunction check, press [Save].
Input the file name if necessary.
(8) <Procedure 7/8>
Repeat 5 times from <Procedure 1/8>.
Fuel system parts replacement: go to (9)
Fuel system malfunction check: go to (10)
(9) <Procedure 8-a/8>
Keep idling over 3min.
(10) <Procedure 8-b/8>
At <Procedure 1/8> screen, press [Proj info].
Select the saved data in 'Fuel System Check' folder, in
Individual data list window.
Display and confirm the graph from saved data.
1KD_RM.book 29 ページ 2013年9月27日 金曜日 午後12時47分
1-30
CIRCUIT DIAGRAM
Ignition
switch
Glow plug
Turbo
charger
S/A
Starter
Accelerator
position
sensor
Battery
GLOW
GLOW
GREL
AM1
IGSW
STA
ST
STA
EFI2
EFI
BATT
VNM+
VNM-
EDU
VNVC
MAIN
VNA
VNE2
+B2
+B
MREL
VCPA
VPA
EPA
VCP2
VPA2
EPA2
A B
Parking brake
switch
ECU-IG
Neutral
start relay
ST
T/C shift switch
MAIN
1KD_RM.book 30 ページ 2013年9月27日 金曜日 午後12時47分
1-31
Fuel pressure sensor
Suction control
valve ASSY
Injector driver
Injector ASSY (No.1)
Injector ASSY (No.2)
Injector ASSY (No.3)
Injector ASSY (No.4)
Intake air flow meter
Fuel filter pool switch
Crank position sensor
Crank position
sensor No.2
Electric EGR
control valve
A B
EDU
IJ1+
IJ1-
IJ2-
IJ2+
IJ3-
IJ3+
IJ4-
IJ4+
GND
+B
#10
#20
#30
#40
INJF
VCS1
PCR1
E2S1
PCV+
PCV-
EGM+
EGM-
VCEG
EGRA
EEGL
NE+
NE-
G+
G-
IREL
#1
#3
#2
INJ1
#4
E2G
VG
THA
ETHA
P
1KD_RM.book 31 ページ 2013年9月27日 金曜日 午後12時47分
1-32
Inlet air temperature sensor
Water temperature sensor
Fuel filter clogging switch
Alternator
Fuel temperature sensor
Diesel turbo
pressure sensor
Combination meter ASSY
SAS/OPS controller
Atmospheric
pressure sensor
THF
ALT
ETHF
CAN+
FPSW
PIM
VCPM
EPIM
EC
CAN-
THIA
ETHI
THW
ETHW
W
GIND
THWO
W3
TC
CANH
CANL
E02
E01
E1
ME01
OBD
Diagnostic
connector
TC
E
1KD_RM.book 32 ページ 2013年9月27日 金曜日 午後12時47分
1-33
ECU TERMINAL LAYOUT
Reference
Terminal number
[Terminal symbol]
Input
Output
Measurement condition Reference value
B53 - B56 [VPA - EPA] Input
Accelerator fully closed 0.5 to 1.1 V
Accelerator fully opened 2.6 to 4.5 V
B54 - B58 [VPA2 - EPA2] Input
Accelerator fully closed 1.2 to 2.0 V
Accelerator fully opened 3.4 to 5.0 V
B43 - A109 [STA - E1] Input During cranking 6 V or more
B32 [EC] - Engine ground Ground Always Less than 1 Ω
B12 - A109 [W - E1] Output
When the engine check indicator turns
on (Ignition key switch ON)
0 to 3 V
During idling
(When the engine check indicator does
not turn on)
11 to 14 V
A B
A
B
1
2
3
20
21
22
4
5
6
12
13
14
23
24
25
7
8
9
15
16
17
26
27
28
11 10
18
19
29
30
4
5
6
7
8
9
11 10
12
13
14
15
16
17
18
19 1
2
3
24
25
26
27
28
29
30
20
21
22
23
55
37 36 35 34 33 32 31
53 52 51 50 49 48 47
54
39 38
61 60 59 58 57 56
63 62
40
41
42
43
44
45
46
31
32
33
50
51
52
34
35
36
42
43
44
53
54
55
37
38
39
45
46
47
56
57
58
41 40
48
49
59
60
67
68
69
70
71
72
74 73
75
76
77
78
79
80 64
65
66
87
88
89
90
91
92
93
118
100 99 98 97 96 95 94
116 115 114 113 112 111 110
117
102101
124123122121120119
126125
103
81
82
83
84
85
86
104
105
106
107
108
109
#4
#3
#2
#1
INJ1
ALT P
GREL
FPSW
CAN+
CAN-
E01 E02 VNM- VNM+ PCV+
VCS1
THIA
ETHI
E2S1
THF
ETHF
PCR1
THW
ETHW
VG
THA
ETHA
E2G
VCEG
VNE2
EPIM
PIM
VNVC
VNA
VCPM
EGRA
EEGL
PCV-
NE+ NE-
G+ G-
E1
EGM+ EGM- ME01
+B
EC
BATT
+B2
EPA
MREL
VCPA
IREL
VPA2
STA
VPA
TC IGSW
W3 CANH CANL
W
EPA2 VCP2
THWO
GIND
1KD_RM.book 33 ページ 2013年9月27日 金曜日 午後12時47分
1-34
B2 - A109 [BATT - E1] Input Always 11 to 14 V
B1 - A109 [+B - E1] Input
Engine stop
Ignition key switch ON
11 to 14 V
B20 - A109 [+B2 - E1] Input
Engine stop
Ignition key switch ON
11 to 14 V
B55 - B56 [VCPA - EPA] Output
Engine stop
Ignition key switch ON
4.5 to 5.5 V
B57 - B58 [VCP2 - EPA2] Output
Engine stop
Ignition key switch ON
4.5 to 5.5 V
B45 - A109 [MREL - E1] Output
Engine stop
Ignition key switch ON
11 to 14 V
Engine stop
10 seconds or more elapsed after igni-
tion key switch turns off
0 to 1.5 V
B44 - A109 [IREL - E1] Output During idling 0 to 1.5 V
B38 - A109 [THWO - E1] Output During idling
Pulse generation
(Waveform 1)
B30 - A109 [GIND - E1] Output
Ignition key switch ON, While the glow
indicator turns on
0 to 3 V
After warm-up, during idling 11 to 14 V
B26 - A109 [TC - E1] Input
Ignition key switch ON 11 to 14 V
Short-circuit between the terminals TC
and E of the diagnostic connector
0 to 1.5 V
B25 - A109 [IGSW - E1] Input
Engine stop
Ignition key switch ON
11 to 14 V
B7 - A109 [CANH - E1]
Input and
output
Engine stop
Ignition key switch ON
Pulse generation
(Waveform 2)
B6 - A109 [CANL - E1]
Input and
output
Engine stop
Ignition key switch ON
Pulse generation
(Waveform 3)
A113 - A90 [THIA - ETHI] Input
Intake temperature 0 to 80 °C
(32 to 176 °F) (during warm-up)
0.5 to 3.4 V
A112 - A89 [THF - ETHF] Input
Ignition key switch ON (when cool) 0.5 to 3.4 V
Fuel temperature 20 °C (68 °F) 2.0 to 2.7 V
A111 - A88 [THW - ETHW] Input
Cooling water temperature 60 to 120 °C
(140 to 248 °F) (during warm-up)
0.2 to 1.0 V
A110 - A87 [THA - ETHA] Input
Intake temperature 0 to 80 °C
(32 to 176 °F) (during warm-up)
0.5 to 3.4 V
A67 [E2S1] - Engine ground Ground Always Less than 1 Ω
A68 - A67 [VCS1 - E2S1] Output
Engine stop
Ignition key switch ON
4.5 to 5.5 V
A66 - A67 [PCR1 - E2S1] Input After warm-up, during idling 1.7 to 2.2 V
A65 - A64 [VG - E2G] Input After warm-up, during idling Pulse generation
A64 [E2G] - Engine ground Ground Always Less than 1 Ω
A51 - A109 [INJ1 - E1] Input After warm-up, during racing
Pulse generation
(Waveform 4)
A50 - A109 [#1 - E1] Output After warm-up, during idling
Pulse generation
(Waveform 5)
A49 - A109 [#2 - E1] Output After warm-up, during idling
Pulse generation
(Waveform 5)
A48 - A109 [#3 - E1] Output After warm-up, during idling
Pulse generation
(Waveform 5)
A47 - A109 [#4 - E1] Output After warm-up, during idling
Pulse generation
(Waveform 5)
Terminal number
[Terminal symbol]
Input
Output
Measurement condition Reference value
1KD_RM.book 34 ページ 2013年9月27日 金曜日 午後12時47分
1-35
Terminal number
[Terminal symbol]
Input
Output
Measurement condition Reference value
B2 - A109 [BATT - E1] Input Always 11 to 14 V
B1 - A109 [+B - E1] Input
Engine stop
Ignition key switch ON
11 to 14 V
B20 - A109 [+B2 - E1] Input
Engine stop
Ignition key switch ON
11 to 14 V
B55 - B56 [VCPA - EPA] Output
Engine stop
Ignition key switch ON
4.5 to 5.5 V
B57 - B58 [VCP2 - EPA2] Output
Engine stop
Ignition key switch ON
4.5 to 5.5 V
B45 - A109 [MREL - E1] Output
Engine stop
Ignition key switch ON
11 to 14 V
Engine stop
10 seconds or more elapsed after
ignition key switch turns off
0 to 1.5 V
B44 - A109 [IREL - E1] Output During idling 0 to 1.5 V
B38 - A109 [THWO - E1] Output During idling
Pulse Generation
(Waveform 1)
B30 - A109 [GIND - E1] Output
Ignition key switch ON, While the glow
indicator turns on
0 to 3 V
After warm-up, during idling 11 to 14 V
B26 - A109 [TC - E1] Input
Ignition key switch ON 11 to 14 V
Short-circuit between the terminals TC
and E of the diagnostic connector
0 to 1.5 V
B25 - A109 [IGSW - E1] Input
Engine stop
Ignition key switch ON
11 to 14 V
B7 - A109 [CANH - E1]
Input and
output
Engine stop
Ignition key switch ON
Pulse generation
(Waveform 2)
B6 - A109 [CANL - E1]
Input and
output
Engine stop
Ignition key switch ON
Pulse generation
(Waveform 3)
A113 - A90 [THIA - ETHI] Input
Intake temperature 0 to 80 °C
(32 to 176 °F)
0.5 to 3.4 V
A112 - A89 [THF - ETHF] Input
Ignition key switch ON (when cool) 0.5 to 3.4 V
Fuel temperature 20 °C (68 °F) 2.0 to 2.7 V
A111 - A88 [THW - ETHW] Input
Cooling water temperature 60 to 120 °C
(140 to 248 °F)
0.2 to 1.0 V
A110 - A87 [THA - ETHA] Input
Intake temperature 0 to 80 °C
(32 to 176 °F)
0.5 to 3.4 V
A67 [E2S1] - Engine ground Ground Always Less than 1 Ω
A68 - A67 [VCS1 - E2S1] Output
Engine stop
Ignition key switch ON
4.5 to 5.5 V
A66 - A67 [PCR1 - E2S1] Input After warm-up, during idling 1.7 to 2.2 V
A65 - A64 [VG - E2G] Input After warm-up, during idling Pulse Generation
A64 [E2G] - Engine ground Ground Always Less than 1 Ω
A51 - A109 [INJ1 - E1] Input After warm-up, during racing
Pulse Generation
(Waveform 4)
A50 - A109 [#1 - E1] Output After warm-up, during idling
Pulse Generation
(Waveform 5)
A49 - A109 [#2 - E1] Output After warm-up, during idling
Pulse generation
(Waveform 5)
A48 - A109 [#3 - E1] Output After warm-up, during idling
Pulse generation
(Waveform 5)
A47 - A109 [#4 - E1] Output After warm-up, during idling
Pulse generation
(Waveform 5)
1-36
1. Oscilloscope waveform
(1) Waveform 1
Note:
Depending on cooling water temperature, A changes.
(2) Waveform 2
(3) Waveform 3
(4) Waveform 4
Note:
As the engine speed increases, the waveform cycle gets
shorter.
GND
A
A
Item Description
Measurement
terminals
THWO - E1
Gauge set 5 V/DIV, 100 ms/DIV
Conditions During idling
Water temperature A
30 °C (86 °F) 16 ms
90 °C (194 °F) 278.5 ms
120 °C (248 °F) or
more
385 ms
GND
Item Description
Measurement
terminals
CANH - E1
CAN+ - E1
Gauge set 1 V/DIV, 10 ms/DIV
Conditions
Engine stop
Ignition key switch ON
GND
Item Description
Measurement
terminals
CANL - E1
CAN- - E1
Gauge set 1 V/DIV, 10 ms/DIV
Conditions
Engine stop
Ignition key switch ON
GND
Item Description
Measurement
terminals
CH1: INJ1 - E1
Gauge set 2 V/DIV, 1 ms/DIV
Conditions After warm-up, during racing
1KD_RM.book 36 ページ 2013年9月27日 金曜日 午後12時47分
1-37
(5) Waveform 5
Note:
As the engine speed increases, the waveform cycle gets
shorter.
(6) Waveform 6
(7) Waveform 7
Note:
• As the engine speed increases, each amplitude becomes
larger.
• As the engine speed increases, the waveform cycle gets
shorter.
(8) Waveform 8
GND
GND
GND
GND
CH1
CH3
CH4
CH2
Item Description
Measurement
terminals
CH1: #1 - E1
CH2: #2 - E1
CH3: #3 - E1
CH4: #4 - E1
Gauge set 5 V/DIV, 20 ms/DIV
Conditions After warm-up, during idling
GND
Item Description
Measurement
terminals
ALT - E1
Gauge set 5 V/DIV, 5 ms/DIV
Conditions During idling
GND
GND
CH1
CH2
Item Description
Measurement
terminals
CH1: NE+ - NE-
CH2: G+ - G-
Gauge set 5 V/DIV, 20 ms/DIV
Conditions After warm-up, during idling
GND
GND
CH1
CH2
Item Description
Measurement
terminals
CH1: PCV+ - E1
CH2: PCV- - E1
Gauge set
CH1: 10 V/DIV, 5 ms/DIV
CH2: 500 mv/DIV, 5 ms/DIV
Conditions After warm-up, during idling
1KD_RM.book 37 ページ 2013年9月27日 金曜日 午後12時47分
1-38
(9) Waveform 9
Note:
The waveform depends on operations of the turbo charger S/
A.
(10) Waveform 10
Note:
The waveform depends on operations of the turbo charger S/
A.
Item Description
Measurement
terminals
VNM+ - E1
Gauge set 5 V/DIV, 20 ms/DIV
Conditions After warm-up, during idling
Item Description
Measurement
terminals
VNM- - E1
Gauge set 5 V/DIV, 50 ms/DIV
Conditions After warm-up, during idling
1KD_RM.book 38 ページ 2013年9月27日 金曜日 午後12時47分
1-39
ECU DATA MONITOR/ACTIVE TEST
1. List of ECU data monitor
(1) With SST, according to the instruction of the screen, display [Data monitor] to inspect computer data.
Note:
• To check the standard, unless otherwise specified, completely warm up the engine, disable all of outside
loads, select the N range, and power off each accessory.
• Results of the inspection in the actual machine are reference values, so actual values may be different
depending on regions or weather.
SST 09111-36760-71(09991-70201)
Item name
Description/
Display range
Reference Remarks
Engine Speed
• Indicates engine
speed.
• Display range:
0 to 6000 r/min
• 50 to 400 r/min:
During cranking
• 700 to 800 r/min:
After engine warm-
up, during idling
• It displays a value output from the crank position
sensor No.2.
• If the crank position sensor No.2 does not oper-
ate properly, the engine speed becomes about 0
r/min or is remarkably different from the actual
engine speed.
Calculate
Load
• Indicates engine
load.
• Display range:
0 to 100%
13 to 25%:
After engine warm-up,
during idling (Disable
all of outside loads, N
range)
• It displays a value calculated by the engine con-
trol computer.
• Engine load value =
(Actual fuel injection amount/Maximum fuel injec-
tion amount in the current engine speed) x 100
MAF
• Indicates intake air
quantity.
• Display range:
0 to 655.35 g/sec
(0 to 86.69 lb/min)
• 16 to 24 g/sec (2.12
to 3.17 lb/min):
After engine warm-
up, during idling
• 40 to 65 g/sec (5.29
to 8.60 lb/min):
For engine speed
NMR (No Load Max-
imum Revolution)
Note:
It changes depend-
ing on the amount of
EGR.
• It displays a value output from the intake air flow
meter S/A.
• Based on intake air quantity, the engine control
computer controls fuel injection amount, injection
timing, EGR, and others.
• When intake air quantity is always about 0 g/sec
(0 lb/min):
- The power circuit of the intake air flow meter S/
A is disconnected.
- The VG circuit is disconnected or short-cir-
cuited.
- The EVG circuit is disconnected.
Symptoms when outside the reference:
Rough idling
Atmosphere
Pressure
• Atmospheric pres-
sure value.
• Display range:
0 to 250 kPa
Actual atmospheric
pressure
• With ignition key switch turned on, when a differ-
ence between a value of the atmospheric pres-
sure sensor and that of the intake manifold
pressure sensor is 10 kPa or more, either sensor
has an abnormality.
• With ignition key switch turned on, when atmo-
spheric pressure is 0 kPa or 140 kPa, the sensor
circuit is abnormal.
• Standard atmospheric pressure: 101 kPa
• Atmospheric pressure decreases by 1 kPa with
each lifting of 100 m (328 ft). This changes
depending on weather (high or low atmospheric
pressure).
• The atmospheric pressure sensor is contained in
the engine control computer.
1KD_RM.book 39 ページ 2013年9月27日 金曜日 午後12時47分
1-40
ECU DATA MONITOR/ACTIVE TEST
1. List of ECU data monitor
(1) With 'Engine Diagnostic Program', according to the instruction of the screen, display [Data monitor] to
inspect computer data.
NOTICE:
• To check the reference, unless otherwise specified, completely warm up the engine, disable all of outside
loads, select the N range, and power off each accessory.
• Results of the inspection in the actual machine are reference values, so actual values may be different
depending on regions or weather.
SST: 09240-36770-71
Item Name
Description/
Display Range
Reference Remarks
Engine
Speed
• Indicates engine speed
• Display range:
0 to 6000 rpm
• 50 to 400 rpm: During
cranking
• Refer to repair manual of
the vehicle: After engine
warm-up, during idling
• It displays a value output from the
crank position sensor No. 2.
• If the crank position sensor No. 2 does
not operate properly, the engine
speed becomes about 0 rpm or is
remarkably different from the actual
engine speed.
Calculate
Load
• Indicates engine load.
• Display range:
0 to 100%
10 to 30%:
After engine warm-up, during
idling (disable all of outside
loads, N range)
• It displays a value calculated by the
engine control computer.
• Engine load value =
(Actual fuel injection
amount/Maximum fuel injection
amount in the current engine speed) x
100
MAF • Indicates intake air
quantity.
• Display range: 0 to
655.35 g/sec (0 to
86.69 lb/min)
• 6 to 25 g/sec (0.79 to 3.17
lb/min): After engine warm-
up, during idling
• 30 to 80 g/sec (3.96 to 10.6
lb/min): For engine speed
NMR
NOTE:
It changes depending on
the amount of EGR.
• It displays a value output from the
intake air flow meter S/A.
• Based on intake air quantity, the
engine control computer controls fuel
injection amount, injection timing,
EGR, and others.
• When intake air quantity is always
about 0 g/sec (0 lb/min):
-The power circuit of the intake air
flow meter S/A is disconnected.
-The VG circuit is disconnected or
short-circuited.
-The EVG circuit is disconnected.
Symptoms when outside the reference:
-Rough Idling
Atmosphere
Pressure
• Atmospheric pressure
value.
• Display range: 0 to 255
kPa
Actual atmospheric pressure • With ignition key switch turned on,
when a difference between a value of
the atmospheric pressure sensor and
that of the intake manifold pressure
sensor is 10kPa or more, either
sensor has an abnormality.
• With ignition key switch turned on,
when atmospheric pressure is 0kPa or
140 kPa, the sensor circuit is
abnormal.
• Standard atmospheric pressure: 101
kPa
• Atmospheric pressure decreases by 1
kPa with each lifting of 100 m (328 ft).
This changes depending on weather
(high or low atmospheric pressure).
• The atmospheric pressure sensor is
contained in the engine control
computer.
1-41
Item name
Description/
Display range
Reference Remarks
MAP • Indicates absolute
pressure of the
internal intake
manifold.
• Display range:
0 to 255 kPa
• 90 to 110 kPa
(depending on
atmospheric
pressure): During
idling
• 115 to 160 kPa: For
engine speed NMR
• With ignition key switch turned on or during idling,
intake manifold pressure and atmospheric
pressure are almost the same (standard
atmospheric pressure = 101 kPa).
• With the accelerator fully opened, when intake
manifold pressure is 20 kPa lower than target
supercharging pressure for five seconds or more,
you may feel insufficient output.
• It displays a value output from the diesel turbo
pressure sensor.
Symptoms when outside the reference:
Insufficient output
Coolant Temp • Indicates engine
cooling water tem-
perature.
• Display range:
-40 to 140 °C
(-40 to 284 °F)
70 to 90 °C
(158 to 194 °F):
After engine
warm-up
• When engine cooling water temperature is -40 °C
(-40 °F) or 140 °C (284 °F), the sensor circuit is
disconnected or short-circuited.
• After it is left for a long time, engine cooling water
temperature, intake air temperature, and ambient
temperature become almost the same.
• It displays a value output from the water temper-
ature sensor.
Symptoms when outside the reference: Difficulty in
starting the engine when cool, rough idling, black
smoke, insufficient output
Intake Air • Indicates intake air
temperature.
• Display range:
-40 to 140 °C
(-40 to 284 °F)
A value equal to tem-
perature in the posi-
tion where the intake
air flow meter S/A is
mounted
• After it is left for a long time, engine cooling water
temperature, intake air temperature, and ambient
temperature become almost the same.
• When intake air temperature is -40 °C
(-40 °F) or 140 °C (284 °F), the sensor circuit is
disconnected or short-circuited.
• It displays a value output from the inlet air tem-
perature sensor contained in the intake air flow
meter S/A.
Engine Run
Time
• Indicates rotating
time after the
engine starts.
• Display range:
0 to 65535 sec
Rotating time after the
engine starts
• Indicates elapsed time after the engine starts.
Starter Signal • Indicates starter
signals.
• Display range: ON/
OFF
ON: During cranking Ignition switch (STA) output:
• ON: Indicates that the engine is cranking.
• OFF: Indicates that the engine is not cranking
Although STA is turned off, the starter continues to
operate.
The STA signal abnormality (P0617) is stored.
Injection
Volume
• Indicates fuel injec-
tion amount.
• Display range:
0 to 1279.98 mm3/
st
5 to 15 mm3/st:
During idling (Disable
all of outside loads, N
range)
• It displays fuel injection amount for each combus-
tion.
• For the injector ASSY clogging, low fuel quality,
fuel filter element clogging, or increased engine
friction, fuel injection amount will increase.
• For abnormalities such as low intake manifold
pressure or a small quantity of intake air, fuel
injection amount is limited, which causes insuffi-
cient output.
• It displays a value calculated by the engine con-
trol computer.
1-42
Item Name Description/Display
Range
Reference Remarks
Pilot 1
Injection
Period
 Indicates pilot 1
injection period.
 Display range: 0
to 65535 µs
200 to 300 µs: During idling
(water temperature is less
than 60 °C (140 °F), disable
all of outside loads, N range)
 For symptoms such as knocking, poor
drivability, or white smoke, check pilot 1
injection period. (with or without pilot injection)
 It displays a value calculated by the engine
control computer
Symptoms when outside the reference:
knocking, poor drivability, white smoke
Pilot 2
Injection
Period
 Indicates pilot 2
injection period.
 Display Range: 0
to 65535 µs
200 to 350 µs: During idling
(complete warm-up, disable
all of outside loads, N range)
 For symptoms such as knocking, poor
drivability, or white smoke, check pilot 2
injection period. (with or without pilot injection)
 It displays a value calculated by the engine
control computer.
Symptoms when outside the reference:
knocking, poor drivability, white smoke
Main
Injection
Period
 Indicates main
injection period.
 Display range: 0
to 65535 µs
300 to 600 µs: During idling
(complete warm-up, disable
all of outside loads, N range)
 When fuel pressure becomes 15000 kPa or
less, main injection period becomes 0 µs.
 For engine hard starting, check main injection
period. (with or without injection)
 When P0093, P0627 or P062D is output, the
engine stop request is output. In this case,
main injection period becomes 0 µs.
NOTICE:
After the engine check indicator turns on, in
about one minute the engine stops.
Therefore, inspection cannot be performed
with freeze frame data.
 It displays a value calculated by the engine
control computer
After
Injection
Period
 Indicates after
injection period.
 Display range: 0
to 65535 µs
0 to 400 µs: During idling
(complete warm-up, disable
all of outside loads, N range)
 For symptoms such as black smoke and poor
drivability, check after injection period. (with or
without after injection)
 It displays a value calculated by the engine
control computer.
Pilot 1
Injection
Timing
 Indicates pilot 1
injection timing.
 Display range: -70
to 20 °CA
-14 to -5 °CA: Water
temperature is less than 60 °C
(140 °F), during idling, and the
machine is in the range of
usual atmospheric pressure
 It displays a value calculated by the engine
control computer.
Pilot 2
Injection
Timing
 Indicates pilot 2
injection timing.
 Display range: -50
to 20 °CA
-10 to -2 °CA: After engine
warm-up, during idling, and
the machine is in the range of
usual atmospheric pressure.
 It displays a value calculated by the engine
control computer.
Main
Injection
Timing
 Indicates main
injection timing.
 Display range: -90
to 90 °CA
-3 to 1 °CA: After engine
warm-up, during idling, and
the machine is in the range of
usual atmospheric pressure.
 For symptoms such as poor drivability, black
smoke, or white smoke, check main injection
timing.
 It displays a value calculated by the engine
control computer.
After
Injection
Timing
 Indicates after
injection timing.
 Display range: -10
to 50 °CA
 It displays a value calculated by the engine
control computer.
1-43
1-44
Item Name Description/
Display Range
Reference Remarks
Fuel Press  Indicates fuel
pressure
 Display Range:
0 to 655350 kpa
30000 to 50000kPa:
during idling
(complete warm-up,
disable all of outside
loads, N range)
 Fuel pressure means the actual common rail fuel
pressure.
 Inspect fuel pressure, comparing to common rail
target fuel pressure.
 In the stable condition (during idling after warm-
up) fuel pressure is within 5000 kPa of target
value.
 The engine control computer uses fuel pressure
to perform feedback control of common rail target
fuel pressure.
 Fuel injection amount is determined based on
injection timing and fuel pressure. Injection
patterns are also selected based on fuel pressure.
 Starting the engine requires a minimum of 25000
kPa fuel pressure. (note that when fuel pressure
is about to reach its target, a delay is introduced
even in the normal state)
 When fuel pressure is lower than 25000 kPa,
rough idling may occur.
 When fuel pressure decreases from common rail
target fuel pressure by 20000 kPa, output may be
insufficient.
 When the actual fuel pressure is 40000 kPa
higher than common rail target fuel pressure,
P1229 is output.
 When fuel pressure is lower than a target value,
insufficient output will occur without DTC output.
 When fuel pressure is higher than 250000 kPa,
DTC P0088 is output.
 It displays a value output from the fuel pressure
sensor (common rail assy)
Symptoms when outside the reference: Difficulty
starting the engine, poor drivability, insufficient
output, knocking.
Fuel
Temperature
 Indicates fuel
temperature
 Display range: -
40 to 215°C (-40
to 419°F)
Actual fuel temperature  When the engine is completely cooled, fuel
temperature is equal to ambient temperature.
 It displays a value output from the fuel
temperature sensor.
Target Pump
SCV Current
 Indicates a
target value of
final pump
current.
 Display range: 0
to 8192 mA
1600 to 2000 mA:
during idling (complete
warm-up, disable all
outside loads, N range)
 It displays a calculated value by the engine
control computer for target current for driving the
suction control valve assy and controls a target
value of solenoid current.
 When high fuel pressure is required, a target
value of solenoid current is higher.
 Typically, a target value of solenoid current is in
the range of 800 to 2500 mA.
 When the target value remains a 3000mA or
more, it indicates that the pump is defective.
(such as a defect due to deposit)
 If it is not in the standard, even when the pump
operates actively, the actual fuel pressure does
not match common rail fuel pressure.
Symptoms when outside the reference: Difficulty in
starting the engine, insufficient output, or rough
idling.
1-45
Target EGR
Pos.
Indicates EGR valve
target opening
degree.
Display range:
0 to 100%
0 to 90%:
After engine warm-up,
during idling (com-
plete warm-up, dis-
able all of outside
loads,
N range)
• EGR valve fully opened: 100%
• EGR valve fully closed: 0%
• Inspect it comparing to the actual EGR opening
degree #1.
• EGR target opening degree displays a calculated
value by the engine control computer based on
sensor output values (such as the intake air flow
meter S/A, inlet air temperature sensor (con-
tained in the intake air flow meter S/A), diesel
turbo pressure sensor).
Symptoms when outside the reference:
• When EGR target opening degree is not in the
standard and near 0%, the intake air flow meter
S/A may be abnormal, or an intake or exhaust
system may get clogged.
• When EGR target opening degree is not in the
standard and near 100%, the EGR pipe may get
clogged.
Actual EGR
Valve Pos.
• Indicates EGR
valve actual open-
ing degree.
• Display range:
0 to 100%
0 to 90%:
After engine
warm-up, during idling
(complete warm-up,
disable all of outside
loads,
N range)
• EGR valve fully opened: 100%
• EGR valve fully closed: 0%
• It is effective to judge if the EGR valve is stuck.
• Inspect it comparing to EGR target opening
degree.
• In the active test, check operations of the EGR
valve.
• When the EGR valve becomes abnormal around
a certain temperature, refer to engine cooling
water temperature and outside temperature
which are reference in case of an abnormality.
• The valve position displays a calculated value
output from the EGR valve position sensor.
Symptoms when outside the reference:
• EGR valve stuck open: Hard starting (no engine
stalling), black smoke, white smoke, insufficient
output
• EGR valve stuck close: Increase of turbo super-
charging sound
EGR Close
Lrn. Val.
• Indicates an EGR
fully-closed posi-
tion learned value.
• Display range:
0 to 5.00 V
0 to 1 V
• An EGR fully-closed position learned value is
output voltage from the EGR valve position sen-
sor.
• When the EGR fully-closed position learned
value becomes the upper or lower limit of the nor-
mal range, foreign matter may be involved in the
EGR valve.
• The lower limit of the EGR fully-closed position
learned value is 0 V, and the upper 1 V. When
this value is fixed to either limit, the valve position
sensor may be abnormal, or the valve position
may be misplaced (with foreign matter).
Item name
Description/
Display range
Reference Remarks
1KD_RM.book 45 ページ 2013年9月27日 金曜日 午後12時47分
1-46
EGR Close
Lrn. Status
• Indicates a state of
EGR fully-closed
position learning.
• Display range:
Completed/Not
completed
Completed
• Completed: It means that fully-closed position
learning is normally completed.
• Not completed: It means that the learned fully-
closed position may not in the correct range.
• When it is not completed, foreign matter may be
involved in the EGR valve.
Note:
After the battery cable is disconnected and
then connected, when the ignition key switch is
never turned off, learning may not be com-
pleted.
Results of inspection in the actual machine:
Ignition key switch ON: Completed
EGR
Operation
Prohibit
• Indicates that oper-
ations of EGR are
prohibited.
• Display range: OK/
NG
OK:
In the active test, EGR
target opening degree
bank 1 can be per-
formed.
• OK: In the active test, EGR target opening
degree bank 1 can be performed.
• NG: In the active test, EGR target opening
degree bank 1 cannot be performed.
Target Booster
Pressure
• Indicates target
pressure of super-
charging pressure.
• Display range:
0 to 639.98 kPa
-
• Inspect it comparing to intake manifold pressure.
• With the accelerator fully opened, when intake
manifold pressure is 20 kPa lower than target
supercharging pressure for five seconds or more,
you may feel insufficient output.
• It displays a value calculated by the engine con-
trol computer.
Boost
Pressure
Deviation
• Indicates super-
charging pressure
deviation.
• Display range:
-320 to 320 kPa
-
It displays a difference between target supercharg-
ing pressure and intake manifold pressure.
VN Turbo
Command
• Indicates VN turbo
motor target open-
ing degree.
• Display range:
0 to 100%
0 to 100%
• VN turbo target opening degree is a command of
the engine control computer.
• 0%: The nozzle vane is fully opened.
(The actuation rod is contracted)
• 90% or more: The nozzle vane is fully closed(The
actuation rod is extended)
• When VN turbo target opening degree is large,
the turbo operates effectively.
• The command of the engine control computer
controls nozzle vane opening degree.
Actual VN
Position
• Indicates actual
VNT opening
degree.
• Display range:
0 to 127.5%
0 to 100%
• When movement of the nozzle vane becomes
slow and it is stuck, a difference between this
opening degree and VN turbo target opening
degree is larger, and VN turbo output (duty) also
becomes large.
• VNT actual opening degree is controlled to suit
VN turbo target opening degree.
VN Position
Sensor Out
• Indicates VNT
opening sensor
output voltage.
• Display range:
0 to 4.99 V
1 to 3 V:
After engine
warm-up, during idling
It displays a value output from the nozzle vane
opening degree sensor.
VN Motor Duty
• Indicates the VNT
motor drive duty
ratio.
• Display range:
0 to 127.5%
2 to 88%
When movement of the nozzle vane becomes
slow, output (duty) increases to the direction of
100%.
Item name
Description/
Display range
Reference Remarks
1KD_RM.book 46 ページ 2013年9月27日 金曜日 午後12時47分
1-47
VN Close
Learn Value
• Indicates a VNT
fully-closed learn-
ing voltage value.
• Display range:
0 to 4.99 V
1.0 to 2.0 V -
VN Close
Learn Status
• Indicates a VNT
fully-closed posi-
tion learning his-
tory.
• Display range: ON/
OFF
ON
When VN Close Learning is not completed, the
performance of the machine may decrease. (low
engine output)
VN Turbo
Operation
Prohibit
• Indicates that the
VN turbo active test
is prohibited.
• Display range:
Allowed/Prohibited
Allowed:
VN turbo opening
degree can be per-
formed in the active
test.
When it is prohibited, the engine control computer
does not allow performing the active test for VN
turbo opening degree.
Initial Engine
Coolant Temp
• Indicates engine
cooling water tem-
perature at start-
up.
• Display range:
-40 to 120 °C
(-40 to 248 °F)
Engine cooling water
temperature at start-
up
• With freeze frame data, you can determine if an
abnormality occurred at start-up when cool, or
after the engine warm-up.
• It displays a value output from the water temper-
ature sensor at engine start-up.
Initial Intake
Air Temp
• Indicates initial
intake air tempera-
ture.
• Display range:
-40 to 120 °C
(-40 to 248 °F)
Intake air tempera-
ture at engine start-up
It displays a value output from the intake air flow
meter S/A (intake temperature sensor) at engine
start-up.
Engine Start
Time
• Indicates engine
start time.
• Display range:
0 to 267386 ms
- It displays the time required by engine start-up.
Engine Speed
(Starter Off)
• Indicates engine
speed when the
starter is turned off.
• Display range:
0 to 1593 rpm
-
It displays engine speed immediately after the
engine starts.
Starter Count
• Indicates how
many times the
starter has been
turned on.
• Display range:
0 to 255
-
It displays how many times the starter has been
turned on since ignition key switch was turned on.
Electric Duty
Feedback
Value
• Indicates an electri-
cal load feedback
value.
• Display range:
0 to 39.8 mm3
/st
0 to 5 mm3
/st
After electrical load is turned off and then on, ISC
electrical load correction amount increases.
Item name
Description/
Display range
Reference Remarks
1KD_RM.book 47 ページ 2013年9月27日 金曜日 午後12時47分
1-48
Intake Air
Temp (Turbo)
• Indicates intake air
temperature after
the inter cooler is
passed.
• Display range:
-40 to 190 °C (-40
to 374 °F)
During idling
70 °C (158 °F) or less
• Indicates intake air temperature of the intake
manifold (after the inter cooler ASSY is passed).
• Intake air temperature after turbo charging is set
to 170 °C (338 °F) while the fail safe function is
operating.
• When intake air temperature after turbo charging
becomes high, turbo supercharging pressure is
suppressed, which may cause insufficient output.
• It displays a value output from the inlet air tem-
perature sensor.
Check Mode
• Indicates the check
mode state.
• Display range:
Check/Normal
Check mode state:
Check
Check mode: A particular DTC can be easily
detected at a high sensitivity.
Battery
Voltage
• Indicates battery
voltage.
• Display range:
0 to 15 V
11 to 14 V:
Ignition key switch ON
When it is 11 V or less, characteristics of electronic
parts will be changed.
Symptoms when outside the reference:
When it is 5 V or less, it is difficult to start the
engine.
Alternate Duty
Ratio
• Indicates the alter-
nator power gener-
ation duty ratio.
• Display range:
0 to 100%
-
• It is used to output alternator power generation
duty and to decide electrical load.
• When injection amount during idling is larger than
normal, it is used to determine if there are electri-
cal load or other causes.
• In the state where Alternate Duty Ratio is not
high (low electrical load), when idling injection
amount is large, injection amount of the injector
ASSY may decrease, or engine friction may be
large.
• It is used to judge a power generation request
state due to an abnormal electrical system.
• Whether or not accessories (such as A/C or the
heater) operate, when Alternate Duty Ratio is
always the maximum value, an abnormality
occurs in the electrical system (such as battery
deterioration).
• It displays a duty value from the ALT terminal.
Engine Speed
of Cyl #1
Engine Speed
of Cyl #2
Engine Speed
of Cyl #3
Engine Speed
of Cyl #4
• Indicates cylinder
engine speed.
• Display range:
0 to 51199 rpm
The engine speed of
all cylinders are
almost the same:
Normal
• It is output only when the engine speed is mea-
sured for each cylinder in the active test.
• Indicates engine speed for each cylinder during
cranking.
Example:
- When compression of the No.1 cylinder is low,
Engine Speed of Cyl #1 is about 300 rpm, Engine
Speed of Cyl #2, #3, and #4 is about 200 rpm.
- When compression of the No.2 cylinder is low,
Engine Speed of Cyl #2 is about 300 rpm, Engine
Speed of Cyl #1, #3, and #4 is about 200 rpm.
- When compression of the No.3 cylinder is low,
Engine Speed of Cyl #3 is about 300 rpm, Engine
Speed of Cyl #1, #2, and #4 is about 200 rpm.
- When compression of the No.4 cylinder is low,
Engine Speed of Cyl #4 is about 300 rpm, Engine
Speed of Cyl #1, #2, and #3 is about 200 rpm.
Symptoms when outside the reference:
When the engine speed of all cylinders is not the
same, idling is not stable.
Item name
Description/
Display range
Reference Remarks
1KD_RM.book 48 ページ 2013年9月27日 金曜日 午後12時47分
1-49
Av Engine
Speed of All
Cyl
• Indicates the aver-
age engine speed
of all cylinders.
• Display range:
0 to 51199 rpm
-
• It is output only when the engine speed is mea-
sured for each cylinder in the active test.
• Indicates the average engine speed of all cylin-
ders during cranking.
Time after
DTC Cleared
• Indicates elapsed
time after DTC is
deleted.
• Display range:
0 to 65535 min
Time after DTC is
deleted
It displays elapsed time after DTC is deleted (or
shipped from the factory).
Warm-up
Cycle Cleared
DTC
• Indicates warm-up
count after DTC is
deleted.
• Display range:
0 to 255
-
• It displays engine warm-up count after DTC is
deleted.
• (Warm-up Cycle Cleared DTC of data list is
deleted) - (Warm-up Cycle Cleared DTC of
freeze frame data is deleted) = Warm-up count
after an abnormality occurs
TC and TE1
• Indicates the con-
nection condition
between TC and
TE1 in the active
test.
• Display range: ON/
OFF
-
When the TE1/TC terminals are turned on in the
active test, the system operates as if the TC termi-
nal and E terminal of the diagnostic connector are
connected.
Isochronous
Control Target
Speed
• Indicates the Isoch-
ronous Control Tar-
get Speed.
• Display range:
0 to 12800 r/min
700 to 800 r/min:
After engine warm-up,
during idling
It displays a value calculated by the engine control
computer.
Isochronous
Control
Proportional
Term
• Indicates the Isoch-
ronous Control
Proportional Term.
• Display range:
-50 to 120 mm3
/st
-
It displays a value calculated by the engine control
computer.
Isochronous
Control
Integral Term
• Indicates the Isoch-
ronous Control
Integral Term.
• Display range:
-80 to 79.997 mm3
/
st
-
It displays a value calculated by the engine control
computer.
Total
Operation
Hours
• Indicates the Total
Operation Hours.
• Display range:
0 to 4500000000
sec
-
It displays a value calculated by the engine control
computer.
Total Number
of Rotations
• Indicates the Total
Number of Rota-
tions.
• Display range:
0 to 4290000000
Rotations
-
It displays a value calculated by the engine control
computer.
Total Injection
Volume
• Indicates the Total
Injection Volume.
• Display range:
0 to 33554432 L
(0 to 8864147 gal)
-
It displays a value calculated by the engine control
computer.
Item name
Description/
Display range
Reference Remarks
1KD_RM.book 49 ページ 2013年9月27日 金曜日 午後12時47分
1-50
Item name
Description/
Display range
Reference Remarks
Av Engine
Speed of All
Cyl
• Indicates the aver-
age engine speed
of all cylinders.
• Display range:
0 to 51199 rpm
- • It is output only when the engine speed is mea-
sured for each cylinder in the active test.
• Indicates the average engine speed of all cylin-
ders during cranking.
Time after
DTC Cleared
• Indicates elapsed
time after DTC is
deleted.
• Display range:
0 to 65535 min
Time after DTC is
deleted
• It displays elapsed time after DTC is deleted (or
shipped from the factory).
Warm-up
Cycle Cleared
DTC
• Indicates warm-up
count after DTC is
deleted.
• Display range:
0 to 255
- • It displays engine warm-up count after DTC is
deleted.
• (Warm-up Cycle Cleared DTC of data list is
deleted) - (Warm-up Cycle Cleared DTC of
freeze frame data is deleted) = Warm-up count
after an abnormality occurs
TC and TE1 • Indicates the con-
nection condition
between TC and
TE1 in the active
test.
• Display range: ON/
OFF
- • When the TE1/TC terminals are turned on in the
active test, the system operates as if the TC ter-
minal and E terminal of the diagnostic connector
are connected.
Isochronous
Control Tar-
get Speed
• Indicates the Isoch-
ronous Control Tar-
get Speed.
• Display range:
0 to 12800 r/min
• It displays a target engine speed with the re-
quest of vehicle is taken.
Refer to repair manual
of the vehicle After
engine warm-up,
during idling
Isochronous
Control
Proportional
Term
• Indicates the Isoch-
ronous Control
Proportional Term.
• Display range:
-50 to 120 mm3/st
- • It displays a value calculated by the engine con-
trol computer.
Isochronous
Control
Integral Term
• Indicates the Isoch-
ronous Control
Integral Term.
• Display range:
-80 to 79.997 mm3/
st
- • It displays a value calculated by the engine con-
trol computer.
Total
Operation
Hours
• Indicates the Total
Operation Hours.
• Display range:
0 to 4500000000
sec
- • It displays a value calculated by the engine con-
trol computer.
Total Number
of Rotations
• Indicates the Total
Number of Rota-
tions.
• Display range:
0 to 4290000000
Rotations
- • It displays a value calculated by the engine con-
trol computer.
Total Injection
Volume
• Indicates the Total
Injection Volume.
• Display range:
0 to 33554432 L
(0 to 8864147 gal)
- • It displays a value calculated by the engine con-
trol computer.
1-51
Item name
Description/
Display range
Reference Remarks
Accel Sensor
Out No.1
(Accurate)
• Indicates the Accel
Sensor Out No.1
(Accurate).
• Display range:
0 to 5.000 V
IG-ON:
0.75 to 0.95 V
(Accel pedal: Close)
-
Accel Sensor
Out No.2
(Accurate)
• Indicates the Accel
Sensor Out No.2
(Accurate).
• Display range:
0 to 5.000 V
IG-ON:
1.35 to 1.55 V
(Accel pedal: Close)
-
Pre Glow • Indicates the Pre
Glow.
• Display range:
ON/OFF
- Pre Glow demand: ON
After Glow • Indicates the After
Glow.
• Display range:
ON/OFF
- After Glow demand: ON
Target Idle
Engine Speed
• Indicates the Tar-
get Idle Engine
Speed.
• Display range:
0 to 10000 r/min
• It displays a target value of the engine individual
• Check "Isochronous Control Target Speed" because it
is not sometimes match with engine speed, while still
installed on the vehicle.
Fuel Return
Temp
• Indicates the Fuel
Return Temp.
• Display range:
-40 to 215 °C
(-40 to 419 °F)
- • It displays a value calculated by the engine con-
trol computer.
EGR Motor
Duty #1
• Indicates the EGR
Motor Duty #1
• Display range:
0 to 127.5 %
0 to 100% • It displays a value calculated by the engine con-
trol computer.
2. Active test
(1) With 'Engine Diagnostic Program', according to the instruction of the screen, display the [Active test] screen
to perform the active test.
SST: 09240-36770-71
Item name Description Constraint condition
Control the Select
Cylinder Fuel Cut
Stop fuel injection of each cylinder #1/
#2/#3/#4 (Injection of multiple cylinders
cannot be stopped.)
With the machine stopped, during engine
rotating
Check the Cylinder
Compression
Stop fuel injection of all cylinders.
Measure engine speed during cranking.
With the machine stopped, when the crank
position sensor and sensor No.2 are in the
normal state
Control the EGR Step
Position
Increase or decrease EGR opening
degree.
When the test is started, opening
degree shall be 0. It can be increased or
decreased in the range of 0 to 100% by
1%.
With the machine stopped, Ignition key
switch ON (Engine stop)
Activate the EGR Valve
Close
Forced closed of the EGR valve With the machine stopped, during engine
rotating after warm-up
1-52
FAIL SAFE LIST
1. Fail safe list
(1) When the codes listed below are recorded in the engine control computer, the machine enters the fail safe
mode.
Diagnosis code Fail safe operation Condition for canceling the fail safe mode
P0046 Limit the engine output. Ignition switch OFF.
P0047 Limit the engine output. Ignition switch OFF.
P0048 Limit the engine output. Ignition switch OFF.
P007C
Intake temperature (after turbo charging) is fixed
to 170 °C (338 °F).
Restore the normal condition.
P007D
Intake temperature (after turbo charging) is fixed
to 170 °C (338 °F).
Restore the normal condition.
P0087 Limit the engine output. Ignition switch OFF.
P0088 Limit the engine output. Ignition switch OFF.
P0093 Limit the engine output. Ignition switch OFF.
P0102 Limit the engine output. Ignition switch OFF.
P0103 Limit the engine output. Ignition switch OFF.
P0107 Intake manifold pressure is fixed to 101.3 kPa. Restore the normal condition.
P0108 Intake manifold pressure is fixed to 101.3 kPa. Restore the normal condition.
P0112 Intake temperature is fixed to 60 °C (140 °F). Restore the normal condition.
P0113 Intake temperature is fixed to 60 °C (140 °F). Restore the normal condition.
P0115
Temperature is fixed to 119 °C (246 °F) when the
fuel temperature sensor is abnormal.
When fuel temperature is 15 °C (59 °F) or less:
Substitute a value of the fuel temperature sensor.
When fuel temperature is 15 °C (59 °F) or more: It
is fixed to 119 °C (246 °F).
Restore the normal condition.
P0117
Temperature is fixed to 119 °C (246 °F) when the
fuel temperature sensor is abnormal.
When fuel temperature is 15 °C (59 °F) or less:
Substitute a value of the fuel temperature sensor.
When fuel temperature is 15 °C (59 °F) or more: It
is fixed to 119 °C (246 °F).
Restore the normal condition.
P0118
Temperature is fixed to 119 °C (246 °F) when the
fuel temperature sensor is abnormal.
When fuel temperature is 15 °C (59 °F) or less:
Substitute a value of the fuel temperature sensor.
Restore the normal condition.
P0180 Fuel temperature is fixed to 50 °C (122 °F). Restore the normal condition.
P0182 Fuel temperature is fixed to 50 °C (122 °F). Restore the normal condition.
P0183 Fuel temperature is fixed to 50 °C (122 °F). Restore the normal condition.
P0190 Limit the engine output. Ignition switch OFF.
P0192 Limit the engine output. Ignition switch OFF.
P0193 Limit the engine output. Ignition switch OFF.
P0201 Limit the engine output.
Turn the ignition switch OFF and then ON.
Alternatively, turn STA ON.
P0202 Limit the engine output.
Turn the ignition switch OFF and then ON.
Alternatively, turn STA ON.
P0203 Limit the engine output.
Turn the ignition switch OFF and then ON.
Alternatively, turn STA ON.
1KD_RM.book 52 ページ 2013年9月27日 金曜日 午後12時47分
1-53
P0204 Limit the engine output.
Turn the ignition switch OFF and then ON.
Alternatively, turn STA ON.
P0299 Limit the engine output. Restore the normal condition.
P0335 Limit the engine output. Restore the normal condition.
P0339 Limit the engine output. Restore the normal condition.
P0340 Limit the engine output. Restore the normal condition.
P0405 Limit the engine output. Ignition switch OFF.
P0406 Limit the engine output. Ignition switch OFF.
P042E Limit the engine output. Ignition switch OFF.
P0489 Limit the engine output. Ignition switch OFF.
P0490 Limit the engine output. Ignition switch OFF.
P0606 Limit the engine output. Restore the normal condition.
P060A Limit the engine output. Restore the normal condition.
P060B Limit the engine output. Restore the normal condition.
P0627 Limit the engine output. Restore the normal condition.
P062D
When only one cylinder is abnormal, engine out-
put is limited.
When two or more cylinders are abnormal, the
engine stalls.
Ignition switch OFF.
P1229 Limit the engine output. Ignition switch OFF.
P1251 Limit the engine output. Ignition switch OFF.
P2120 Limit the engine output. Restore the normal condition.
P2121 Limit the engine output. Restore the normal condition.
P2122 Limit the engine output. Restore the normal condition.
P2123 Limit the engine output. Restore the normal condition.
P2125 Limit the engine output. Restore the normal condition.
P2127 Limit the engine output. Restore the normal condition.
P2128 Limit the engine output. Restore the normal condition.
P2138 Limit the engine output. Restore the normal condition.
P2226 Atmospheric pressure is fixed to 70 kPa. Restore the normal condition.
P2228 Atmospheric pressure is fixed to 70 kPa. Restore the normal condition.
P2229 Atmospheric pressure is fixed to 70 kPa. Restore the normal condition.
P2564 Limit the engine output. Ignition switch OFF.
P2565 Limit the engine output. Ignition switch OFF.
U0101 Limit the engine output. Restore the normal condition.
Diagnosis code Fail safe operation Condition for canceling the fail safe mode
1KD_RM.book 53 ページ 2013年9月27日 金曜日 午後12時47分
1-54
Circuit description
The VN turbo charger system consists of the VN turbo charger actuator and the engine control computer. The VN
turbo charger has a variable nozzle vane. When the vane is opened and closed, the area of the turbine inlet will be
changed. This allows adjustment of pressure and speed of exhaust gas entering the turbine. When the vane is
closed, supercharging pressure gets higher. When it is opened, supercharging pressure gets lower.
The VN turbo charger actuator consists of the DC motor and the nozzle opening degree sensor. The nozzle opening
degree sensor detects opening degree of the variable nozzle vane. The DC motor controls the variable nozzle vane.
When the engine control computer opens and closes the variable nozzle vane through the DC motor based on the
traveling state, flow speed of exhaust gas is changed, allowing the control of supercharging pressure.
When detecting a disconnection or short-circuit in the DC motor circuit, the engine control computer stores a
diagnosis code and turns on the engine check indicator.
When the variable nozzle vane is stuck close, engine torque when the throttle is opened will be significantly limited.
When the variable nozzle vane is stuck open, a response becomes slow and torque decreases when the throttle is
opened. However, power reduction during high rotation is smaller than that in the stuck close.
P0046
P0047
DTC P0046 Turbocharger Boost Control Circuit Range / Performance
DTC P0047 Turbocharger Boost Control Solenoid Circuit Low
DTC P0048 Turbocharger Boost Control Solenoid Circuit High
DTC check pattern
DTC detection conditions
1. Diagnosis conditions
2. Abnormal status
3. Abnormal period
4. Others
Inspection position
In [Active the VN Turbo Open] of the
activsxe test, keep the open (fully
opened) and OFF (fully closed)
states for five seconds or more.
1. Ignition key switch ON
2. A current of the DC motor is 2.2 A
or more.
3. 5 sec. or longer
4. 1 trip
• Disconnection, short-circuit, and
poor connection of the nozzle
opening degree sensor (turbo
charger S/A).
• DC motor (Turbo charger S/A)
• Wire harness or connector
• Stuck and slow movement of the
nozzle vane
(turbo charger S/A)
• Engine control computer
DTC check pattern
DTC detection conditions
1. Diagnosis conditions
2. Abnormal status
3. Abnormal period
4. Others
Inspection position
In [Active the VN Turbo Open] of the
active test, keep the open (fully
opened) and OFF (fully closed)
states for five seconds or more.
1. Ignition key switch ON
2. A duty ratio of the DC motor is
80% or more, and a current value
is 0.5 A or less.
3. Three seconds or more
4. 1 trip
• DC motor (Turbo charger S/A)
• Wire harness or connector
• Engine control computer
1KD_RM.book 54 ページ 2013年9月27日 金曜日 午後12時47分
1-55
P0048
Note:
• The following symptoms may occur when the nozzle vane is stuck close and then DTC P0046, P0047, and
P0048 are stored.
- Hunting where a recovery operation from power reduction is repeated every a few seconds during high-
load traveling.
• The following symptoms may occur when the nozzle vane is stuck open and then DTC P0046, P0047, and
P0048 are stored.
- Insufficient output
- Rising of the engine torque when the accelerator is depressed becomes slow.
Circuit diagram
Inspection procedure
Caution:
When replacing the engine control computer or injector ASSY, initialize and write the corresponding ID code
according to the Operation Support Procedure List. (See page 1-16 for the procedure.)
Note:
Use 'Engine Diagnostic Program' to read the freeze frame data. A part of engine operation condition when
the defect occurred is recorded in the freeze frame data. This information is useful for troubleshooting.
SST 09111-36760-71(09991-70201)
1. Turn the ignition key switch ON. According to the instruction of
the 'Engine Diagnostic Program' screen, read the diagnosis
code. (See page 1-13 for the procedure.)
Result
DTC check pattern
DTC detection conditions
1. Diagnosis conditions
2. Abnormal status
3. Abnormal period
4. Others
Inspection position
In [Active the VN Turbo Open]
of the active test, keep the open
(fully opened) and OFF (fully closed)
states for five seconds or more.
1. Ignition key switch ON
2. DC motor overcurrent
3. 25 times or more
(about 0.4 second or more)
4. 1 trip
• DC motor (Turbo charger S/A)
• Wire harness or connector
• Engine control computer
A
U
DC motor (Turbo charger S/A) Engine control
Computer
Shield cable
2
1
42
43
VNM+
VNM-
1 Diagnosis code reading
Result Go to
P0046, P0047, or P0048 is output. A
P0046, P0047, P0048, and other diagnosis codes are output. B
1KD_RM.book 55 ページ 2013年9月27日 金曜日 午後12時47分
1-56
A
1. Turn ON the ignition switch.
2. Press [Active test] and select [Test the Turbo Charger Motor]
on the 'Engine Diagnostic Program'.
3. Monitor [VNT Command] and [Actual VN Position] from the
data list items.
4. Implement the active test.
Result
A
1. Disconnect the DC motor (turbo charger S/A) connector.
2. Measure the resistance between terminals.
Resistance
OK
B Go to the related diagnosis code chart
(See page 1-5 for the procedure.)
2 Active test implementation (Test the Turbo Charger Motor)
Result Go to
The value of the [Actual VN Position] follows that of the [VNT Command]. A
The value of the [Actual VN Position] does not follow that of the [VNT Command]. B
B Go to step 3.
INSPECTION OF IRREGULAR PROBLEMS (See page 1-15 for the procedure)
3 Turbo charger S/A inspection (individual inspection)
1
2
DC motor (Turbo charger S/A)
M+ M-
Inspection terminal Inspection condition Standard
2 (M+) - 1 (M-) Always 1 to100 Ω
NG Go to step 6.
4
Wire harness and connector inspection
(DC motor (Turbo charger S/A) - Engine control computer)
1KD_RM.book 56 ページ 2013年9月27日 金曜日 午後12時47分
1-57
Note:
See page 0-13 for the inspection procedure and notes of wire
harness and connectors.
1. Disconnect the connector A of engine control computer and
the connector U of DC motor (turbo charger S/A).
2. Measure the resistance between terminals using a tester.
(See page 1-33 for the terminal layout.)
Resistance
Resistance
OK
1. Replace the turbo charger S/A. (See page 2-19 for the
procedure.)
1. Repair or replace the wire harness or connector.
Next
SST 09111-36760-71(09991-70201)
1. Turn ON the ignition switch.
2. According to the instruction of the 'Engine Diagnostic Program'
screen, delete the diagnosis code. (See page 1-13 for the
procedure.)
3. After turning OFF the ignition switch, perform the diagnostic
code reading after 30 seconds.
Next
A
U
1 2
Engine control computer
Connector on the machine side
DC motor (Turbo charger S/A)
Connector on the machine side
42(VNM+) 43(VNM-)
M+ M-
Inspection terminal
Inspection
condition
Standard
A-42 (VNM+) - U-2 (M-) Always Less than 1 Ω
A-43 (VNM-) - U-1 (M+) Always Less than 1 Ω
Inspection terminal
Inspection
condition
Standard
A-42 (VNM+) and U-2 (M-) -
Other terminal
and body ground
Always 10 kΩ or more
A-43 (VNM-) and U-1 (M+) -
Other terminal
and body ground
Always 10 kΩ or more
NG Go to step 6.
5 Turbo charger S/A replacement
Next Go to step 7.
6 Wire harness or connector repair or replacement
7 Diagnosis code deletion
1KD_RM.book 57 ページ 2013年9月27日 金曜日 午後12時47分
1-58
SST 09111-36760-71(09991-70201)
1. Turn ON the ignition switch.
2. Press [Active test]  select [Activate the VN Turbo Open] on
the 'Engine Diagnostic Program'.
3. Perform the active test and keep the open (fully opened) and
OFF (fully closed) states for 5 seconds or more.
4. According to the instruction of the 'Engine Diagnostic Program'
screen, check that no diagnosis code is output. (See page 1-
13 for the procedure.)
Next
8 Diagnosis code reading
End
1KD_RM.book 58 ページ 2013年9月27日 金曜日 午後12時47分
1-59
Circuit description
The inlet air temperature sensor is attached to the intake pipe to measure the intake air temperature. The resistance
value of thermistor included in the inlet air temperature sensor varies with the change in intake air temperature. The
resistance value of thermistor increases as the intake air temperature falls, or decreases as the intake air
temperature rises. The inlet air temperature sensor is connected to the engine control computer, and 5 V power
supply voltage is supplied to the sensor from the THIA terminal of engine control computer via the resistor R. Since
the resistor R and inlet air temperature sensor are connected in series, the resistance value varies with the change in
intake air temperature and also the THIA terminal potential changes. According to this signal, the engine control
computer increases the fuel injection amount or advance the injection timing when the intake air temperature is low
to improve the drivability.
P007C
DTC P007C Charge Air Cooler Temperature Sensor Circuit Low
DTC P007D Charge Air Cooler Temperature Sensor Circuit High
DTC check pattern
DTC detection conditions
1. Diagnosis conditions
2. Abnormal status
3. Abnormal period
4. Others
Inspection position
1 sec. with ignition key switch ON
1. Ignition key switch ON
2. Shorting of inlet air temperature
sensor circuit
3. 0.5 sec. or longer
4. 1 trip
• Wire harness or connector
• Inlet air temperature sensor (for
intake manifold)
• Engine control computer
Resistance
[kΩ]
Temperature [°C]
30
20
10
5
3
2
1
0.5
0.3
0.2
0.1
-20 0 20 40 60 80 100
1KD_RM.book 59 ページ 2013年9月27日 金曜日 午後12時47分
1-60
P007D
Related Data List
Circuit diagram
Inspection procedure
Caution:
When replacing the engine control computer or injector ASSY, initialize and write the corresponding ID code
according the Operation Support Procedure List.
(See page 1-16 for the procedure.)
Note:
Use 'Engine Diagnostic Program' to read the freeze frame data. A part of engine operation condition when
the defect occurred is recorded in the freeze frame data. This information is useful for troubleshooting.
DTC check pattern
DTC detection conditions
1. Diagnosis conditions
2. Abnormal status
3. Abnormal period
4. Others
Inspection position
1 sec. with ignition key switch ON
1. Ignition key switch ON
2. Disconnection of inlet air temper-
ature sensor circuit
3. 0.5 sec. or longer
4. 1 trip
• Wire harness or connector
• Inlet air temperature sensor (for
intake manifold)
• Engine control computer
DTC No. Data list
P007C
P007D
Intake air temperature after turbocharging
A
P
Inlet air temperature
sensor (for intake manifold) Engine control computer
2
1
113
90
THIA
ETHI
1KD_RM.book 60 ページ 2013年9月27日 金曜日 午後12時47分
1-61
SST 09111-36760-71(09991-70201)
1. Turn the ignition key switch ON and read [Intake Air Temp
(Turbo)] displayed on the 'Engine Diagnostic Program' while
the engine is stopped.
Result
Note:
*: The result is normal at the moment but should be checked
if the defect reappears.
(See page 1-15 for Inspection of irregular problems)
A
SST(1) 09111-36760-71(09991-70201)
SST(2) 09160-36760-71(09843-18040)
1. Disconnect the connector P of inlet air temperature sensor.
2. Using 'diagnosis check wire No.2', short circuit the terminals
between the terminal 1 and 2 of inlet air temperature sensor
connector of the truck side.
3. Turn the ignition key switch ON.
4. Read [Intake Air Temp (Turbo)] displayed on the 'Engine
Diagnostic Program'.
Standard Display temperature 190 °C (374 °F)
NG
1 'Engine Diagnostic Program' data reading (intake air temperature after turbocharging)
Result Go to
-40 °C (-40 °F) (disconnection) A
190 °C (374 °F) (short circuit) B
Same as temperature around intake manifold* C
B Go to step 4.
C Go to step 9.
2 'Engine Diagnostic Program' data reading (wire harness disconnection check)
1 2
P
Inlet air temperature
sensor (for intake manifold)
Connector on the machine side
Inlet air
temperature
Sensor
Engine
control
Computer
OK Go to step 7.
1KD_RM.book 61 ページ 2013年9月27日 金曜日 午後12時47分
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
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Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual
Toyota 1KD Engine Repair Manual

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Toyota 1KD Engine Repair Manual

  • 1. 1-1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 TROUBLESHOOTING ECD (ELECTRONIC CONTROL DIESEL) SYSTEM........................................................................ 1-2 CAUTIONS ...................................................................... 1-2 FUNCTION INSPECTION ............................................... 1-2 BASIC INSPECTION....................................................... 1-2 PARTS LAYOUT DRAWING ........................................... 1-4 DIAGNOSIS CODE LIST................................................. 1-5 LIST OF SYMPTOMS...................................................... 1-7 DESCRIPTION OF FUNCTION..................................... 1-10 PROCEDURE FOR TROUBLESHOOTING.................. 1-11 INSPECTING/DELETING DIAGNOSIS CODE ............. 1-13 FREEZE FRAME DATA/DIAGNOSIS DETAILED INFORMATION ........................................ 1-14 INSPECTION OF IRREGULAR PROBLEMS ............... 1-15 WORK SUPPORT ......................................................... 1-16 CIRCUIT DIAGRAM ...................................................... 1-30 ECU TERMINAL LAYOUT ............................................ 1-33 ECU DATA MONITOR/ACTIVE TEST........................... 1-39 FAIL SAFE LIST............................................................ 1-52 INDIVIDUAL INSPECTION ...................................... 1-293 INTAKE AIR FLOW METER S/A INSPECTION ......... 1-294 1KD_RM.book 1 ページ 2013年9月27日 金曜日 午後12時47分
  • 2. 1-2 1KD_RM.book 2 ページ 2013年9月27日 金曜日 午後12時47分
  • 3. 1-2 ECD (ELECTRONIC CONTROL DIESEL) SYSTEM CAUTIONS 1. Precautions for using the 'Engine Diagnostic Program' WARNING: • Read the 'Engine Diagnostic Program' instruction manual before using it. • In operating the machine with the 'Engine Diagnostic Program' connected, be careful of handling so that the cable of the 'Engine Diagnostic Program' does not hang on the pedal, the shift lever, or the steering wheel. • In operating the machine using the tool (such as performing a simulation test), to avoid operations while controlling the tool, two operators should always work and observe work rules. FUNCTION INSPECTION 1. Accelerator position sensor (potentiometer) (See the lift truck repair manual for the procedure.) 2. Intake air flow meter Caution: • Follow the procedure below to inspect the intake air flow meter S/A. • With the engine stopped, when a value of [MAF] from [Data monitor] does not meet the standard or when foreign matter is found in the platinum filament (heater) portion of the intake air flow meter S/A, the meter should be replaced. (1) Intake air quantity inspection SST 09111-36760-71 (09991-70201) Caution: • With the engine stopped, keep the machine horizontal and inspect these functions indoors. • Perform inspection with the intake air flow meter S/A mounted on the intake pipe (with the machine installed). • Do not suck air from the exhaust tail pipe in the exhaust duct. (a) Turn the ignition key switch on and wait for 30 seconds. (with the engine stopped) (b) According to the instruction of the 'Engine Diagnostic Program' screen, press [Data monitor] and monitor [MAF] and read a numerical value. Reference 1.2 g/sec (0.16 lb/min) or less (2) Sensor foreign matter adhesion inspection (a) Visually check the platinum filament (heater) portion in flow paths. Standard No foreign matter that can be visually checked Note: After checking that no foreign matter is found, return the intake air flow meter S/A to the machine. BASIC INSPECTION Note: When the location of a defect cannot be identified even after troubleshooting, it can be pinpointed through the basic inspection below. 1. Battery inspection (See the machine repair manual for the procedure.) 2. Cranking operation inspection (1) Inspect if the engine cranks. Note: If it does not crank, inspect relevant portions, referring to the LIST OF SYMPTOMS (See page 1-7 for the procedure.) 1KD_RM.book 2 ページ 2013年9月27日 金曜日 午後12時47分
  • 4. 1-3 3. Engine start inspection (1) Inspect if the engine starts. NOTICE: • Engine should be cranked by two rotations at minimum when engine starting because ECD system electrically detects the fuel injected cylinder. • If it does not start, inspect relevant portions, referring to the LIST OF SYMPTOMS (See page 1-8 for the procedure.) 4. Air filter inspection (See the machine repair manual for the procedure.) 5. Idle speed inspection (1) Inspect idling. Reference: Refer to repair manual of the vehicle (after warm-up, during idling) 6. Fuel pressure inspection SST: 09240-36770-71 (1) According to the instruction of the screen, press [Data monitor] and monitor [Fuel Press] and measure fuel pressure. Reference: 30000 to 50000 kPa (after warm-up, during idling) 7. Fuel property Inspect if a proper fuel is used as described in the Operator's Manual. Diesel fuel For 8FD35U to 8FD80U model Use only ultra low-sulfur fuel defined by ASTM D0975 No.2-D S15. Refer to the following table for details. Detailed Requirement for ASTM D0975 No.2-D S15 Property Unit Value Distillation Temperature °C 90 % 282 to 338 Kinematic Viscosity mm2/s at 40 °C 1.9 to 4.1 Sulfur ppm (μ g/g) max 15 Cetane index -, min 40 Aromaticity %vol, max 35 Lubricity, HFRR μm, max 520 NOTICE: • Do not use bio-diesel fuel. Damage to engine will occur. • In cold weather, use winter diesel fuel to prevent clogging of the fuel filter caused by paraffin precipitation. In hot weather, do not use winter diesel fuel. Damage to engine will occur. • Do not use deteriorated fuel which has been stored for a long period of time or impure fuel in which foreign material, water and etc. is included. • If fuel is frozen or becomes wax-like substance in winter season, engine may be hard starting, rough idle after starting or engine rotation is impossible to increase. In that case, fuel for winter use should be used. Melt the wax generated in the fuel filter by warming.
  • 5. 1-4 PARTS LAYOUT DRAWING Fuel pressure sensor Diesel turbo pressure sensor Common rail ASSY Intake air flow meter Glow plug ASSY Injector ASSY Water temperature sensor Inlet air temperature sensor Crank position sensor No. 2 Electric EGR control valve Oil pressure switch ASSY Crank position sensor Turbo charger S/A Suction control valve ASSY Fuel temperature sensor Pressure limiter 1KD_RM.book 4 ページ 2013年9月27日 金曜日 午後12時47分
  • 6. 1-5 DIAGNOSIS CODE LIST ECD System Diagnosis code Diagnosis item Lamp on Code stored Page for reference P0046 Turbocharger boost control circuit range / performance   1-54 P0047 Turbocharger boost control solenoid circuit low   1-54 P0048 Turbocharger boost control solenoid circuit high   1-54 P007C Charge air cooler temperature sensor circuit low   1-59 P007D Charge air cooler temperature sensor circuit high   1-59 P0087 Fuel rail / system pressure - too low   1-65 P0088 Fuel rail / system pressure - too high   1-72 P0093 Fuel system leak detected - large leak   1-79 P0102 Mass air flow sensor circuit low   1-92 P0103 Mass air flow sensor circuit high   1-92 P0107 Manifold absolute pressure sensor circuit low   1-97 P0108 Manifold absolute pressure sensor circuit high   1-97 P0112 Intake air temperature sensor circuit Low   1-102 P0113 Intake air temperature sensor circuit high   1-102 P0115 Engine coolant temperature sensor circuit   1-108 P0117 Engine coolant temperature sensor circuit low   1-108 P0118 Engine coolant temperature sensor circuit high   1-108 P0180 Fuel temperature sensor "A" circuit   1-113 P0182 Fuel temperature sensor "A" circuit low   1-113 P0183 Fuel temperature sensor "A" circuit high   1-113 P0190 Fuel rail pressure sensor circuit   1-65 P0192 Fuel rail pressure sensor circuit low   1-65 P0193 Fuel rail pressure sensor circuit high   1-65 P0201 Injector circuit / open - (Cylinder 1)   1-118 P0202 Injector circuit / open - (Cylinder 2)   1-118 P0203 Injector circuit / open - (Cylinder 3)   1-118 P0204 Injector circuit / open - (Cylinder 4)   1-118 P0299 Turbocharger underboost   1-131 P0335 Crankshaft position sensor circuit   1-133 P0339 Crankshaft position sensor circuit intermittent ×  1-133 P0340 Camshaft position sensor circuit   1-137 P0405 Exhaust gas recirculation sensor circuit low   1-141 P0406 Exhaust gas recirculation sensor circuit high   1-141 P042E Exhaust gas recirculation control stuck open   1-146 P0489 Exhaust gas recirculation control circuit low   1-151 P0490 Exhaust gas recirculation control circuit high   1-151 P0560 System voltage   1-154 P0606 ECM / PCM processor   1-157 P060A Internal control module monitoring processor performance   1-157 P060B Internal control module A/D processing performance   1-157 P0617 Starter relay circuit high   1-159 1KD_RM.book 5 ページ 2013年9月27日 金曜日 午後12時47分
  • 7. 1-6 P0627 Fuel pump control circuit / open   1-162 P062D Fuel injector driver circuit performance   1-118 P062F Internal control module EEPROM error   1-166 P1229 Fuel pump system   1-169 P1251 Motor for turbocharger control circuit (Intermittent)   1-173 P2120 Pedal position sensor "D" circuit   1-180 P2121 Pedal position sensor "D" circuit range / performance   1-188 P2122 Pedal position sensor "D" circuit low   1-180 P2123 Pedal position sensor "D" circuit high   1-180 P2125 Pedal position sensor "E" circuit   1-180 P2127 Pedal position sensor "E" circuit low   1-180 P2128 Pedal position sensor "E" circuit high   1-180 P2138 Pedal position sensor "D" / "E" voltage correlation   1-180 P2226 Barometric pressure circuit   1-191 P2228 Barometric pressure circuit low   1-191 P2229 Barometric pressure circuit high   1-191 P2564 Turbocharger boost control position sensor "A" circuit low   1-193 P2565 Turbocharger boost control position sensor "A" circuit high   1-193 U0101 Lost communication with can ×  1-197 Diagnosis code Diagnosis item Lamp on Code stored Page for reference 1KD_RM.book 6 ページ 2013年9月27日 金曜日 午後12時47分
  • 8. 1-7 LIST OF SYMPTOMS ECD System Symptom Portion to be inspected Page for reference Does not crank Battery - Starter 5-2 Starting relay - Shift lever position - Fast idling rough Fuel filter - Injector ASSY 1-118 Starter system 1-199 Engine control computer - Suction control valve ASSY 1-296 Fuel pressure sensor 1-296 Intake air flow meter 1-294 Fuel property 1-3 Water temperature sensor 1-295 Fuel piping (blocking from the tank to the supply pump) - Idle speed high Troubleshooting of rough idle and large vibration 1-270 Injector ASSY 1-118 Starter system 1-199 Engine control computer - Suction control valve ASSY 1-296 Fuel pressure sensor 1-296 Water temperature sensor 1-295 Accelerator position sensor (potentiometer) - Idle speed low Troubleshooting of rough idle and large vibration 1-270 Injector ASSY 1-118 Electric EGR control valve 1-296 Compression 2-79 Valve clearance 2-78 Fuel piping - Engine control computer - Suction control valve ASSY 1-296 Fuel pressure sensor 1-296 Idle unstable Troubleshooting of rough idle and large vibration 1-270 Injector ASSY 1-118 Fuel piping - Electric EGR control valve 1-296 Compression 2-79 Valve clearance 2-78 Engine control computer - Suction control valve ASSY 1-296 Fuel pressure sensor 1-296 Fuel property 1-3 Power steering system - Alternator ASSY (external accessory) 7-4 1KD_RM.book 7 ページ 2013年9月27日 金曜日 午後12時47分
  • 9. 1-8 Hunting Injector ASSY 1-118 ECU power supply system 1-290 Compression 2-79 Fuel piping - Valve clearance 2-78 Engine control computer - Suction control valve ASSY 1-296 Fuel pressure sensor 1-296 Fuel property 1-3 Power steering system - Alternator ASSY (external accessory) 7-4 White smoke is discharged Electric EGR control valve 1-296 Injector ASSY 1-118 Fuel filter - Engine control computer - Suction control valve ASSY 1-296 Fuel pressure sensor 1-296 Preheating control circuit system 1-206 Fuel property 1-3 Compression 2-79 Turbo charger oil leak and white smoke 1-234 White smoke 1-224 Black smoke is discharged Troubleshooting of black smoke 1-249 Electric EGR control valve 1-296 Injector ASSY 1-118 Exhaust system clogging - Hard starting, engine stalling Troubleshooting of hard starting and engine stalling 1-212 Starter system 1-199 Preheating control circuit system 1-206 Fuel property 1-3 ECU power supply system 1-290 VC power supply system 1-284 Battery - Lack of power, hesitation, surge (hesitation) Troubleshooting of lack of power, hesitation, and surge (hesi- tation) 1-260 Rough idling, large vibration Troubleshooting of rough idle and large vibration 1-270 ID code writing abnormality 1-16 Knocking, abnormal noise Troubleshooting of knocking and abnormal noise 1-277 Turbo charger S/A noise 1-243 Symptom Portion to be inspected Page for reference 1KD_RM.book 8 ページ 2013年9月27日 金曜日 午後12時47分
  • 10. 1-9 Abnormal engine noise, or noisy engine Note: It is not abnormal phenomenon engine noise becomes higher when engine revolution is decreased to idle state after engine revolution increased higher. And this noise tend to become higher at low temperature, but it is not abnormal phenomenon. Engine status where noise is often heard Example of sound Probable cause NOTE: During idling Rasping sound Water pump bearing defect Put a sound scope on the water pump body to check. • Remove the V-ribbed belt and try to rotate by hand. If the turning feels rough or bumpy to the hand, then the bearing is defective. Squealing sound Squeaking sound Oil seal squeal Apply engine oil from outside the seal, or spray an anti-squealing agent. • The sound gets smaller or stops. Hissing noise Air suction sound Inspect the intake manifold and air cleaner for appropriate installation. • Try plugging the place where the air gets in with engine oil, grease or cloth. Certain engine speed Squealing sound Belt slipping The sound occurs on sudden accelera- tion from idle. • Check if the indicator mark of the V- ribbed belt tensioner ASSY is in the range of the standard value. (See page 2-77 for the procedure.) • Inspect the V-ribbed belt for wear, cracks and adhered oil. Knocking sound Piston side knock Heard from the lower part of the engine. Knocking sound of the connecting rod bearing Knocking sound of the crankshaft bearing Piston pin knocking sound Whistling sound Turbo charger S/A Sound volume and pitch are propor- tional to the turbo charger S/A or engine speed. Whole engine speed Clicking sound Clattering sound Excess valve clearance or faulty contact Adjust the valve clearance. (See page 2-77 for the procedure.) A "raspberry" sound A "put-put" sound Exhaust leak Check by blocking with a wet cloth the likely location of the leak in the exhaust system. • The noise becomes louder when the engine speed is increased. 1KD_RM.book 9 ページ 2013年9月27日 金曜日 午後12時47分
  • 11. 1-10 Excessive engine oil consumption DESCRIPTION OF FUNCTION 1. What is the ID code (compensation code)? (1) For the optional injection characteristic of the injector ASSY, the engine control computer performs different injection period compensation for each injector ASSY. This compensation data is punched as a 30-digit alphanumeric ID code on the head of the injector ASSY. The ID code should be written when the injector ASSY or the engine control computer is replaced. (See page 1-16 for the procedure.) Caution: Improper writing of the ID code can cause rough idling or abnormal noise. Cause Inspection or adjustment areas NOTE: Leaking to the exterior of the engine PCV Engine unit Turbo charger S/A (See page 1-234 for the procedure) Leaking to the interior of the engine Cylinder head S/A Cylinder block S/A Head gasket Oil loss via the piston ring A lot carbon build-up will be visible around the top of the piston. Oil loss via the valve guide Determined by the condition of the carbon adhered to the intake valve cap and the top of the piston, and by the wetness of the valve cap caused by oil. Turbo charger S/A (See page 1-234 for the procedure) Injector ASSY ID code Order in which the ID code is read or written No.1 cylinder No.2 cylinder No.3 cylinder No.4 cylinder 1KD_RM.book 10 ページ 2013年9月27日 金曜日 午後12時47分
  • 12. 1-11 PROCEDURE FOR TROUBLESHOOTING Next 1. Check diagnosis codes and freeze frame data (See page 1-14 for the procedure.) 2. Delete diagnosis codes and freeze frame data (See page 1-13 for the procedure.) 3. Check diagnosis codes again (See page 1-13 for the procedure.) Result A 1. Check the list of diagnosis codes (See page 1-5 for the procedure.) Result 1. Check the list of symptoms (See page 1-7 for the procedure.) Result B 1 Making diagnosis and checking symptoms (See page 6-12 for the procedure.) 2 Checking diagnosis codes Result Go to A code was output. A A code was not output. B B Go to step 4. 3 List of diagnosis codes (main inspection portions) or troubleshooting for each code Result Go to A faulty section was identified. A A faulty section was not identified. B A Go to step 9. B Go to step 6. 4 List of symptoms Result Go to A faulty section was identified. A A faulty section was not identified. B A Go to step 9. 1KD_RM.book 11 ページ 2013年9月27日 金曜日 午後12時47分
  • 13. 1-12 Result B 1. Perform [Data monitor] and [Active test] Result B Next Next Next Next 5 Basic inspection (See page 1-2 for the procedure.) Result Go to A faulty section was identified. A A faulty section was not identified. B A Go to step 9. 6 Inspecting with 'Engine Diagnostic Program' Result Go to A faulty section was identified. A A faulty section was not identified. B A Go to step 9. 7 Inspecting ECU terminal voltage and circuits (See page 1-33 for the procedure.) 8 INSPECTION OF IRREGULAR PROBLEMS (See page 1-15 for the procedure) 9 Repairing defective parts 10 Checking diagnosis codes (See page 1-5 for the procedure.) End 1KD_RM.book 12 ページ 2013年9月27日 金曜日 午後12時47分
  • 14. 1-13 INSPECTING/DELETING DIAGNOSIS CODE Note: • Read the 'Engine Diagnostic Program' instruction manual before using it. • 'Engine Diagnostic Program' enables you to select not only the normal mode but the check mode. In the check mode, abnormality detection sensitivity can be improved, compared to the normal mode. • Perform inspection in the check mode when normal codes are output in the normal mode despite of possible abnormalities in a signal system of each sensor. 1. Preparation before inspection (1) Put the shift position to N. (2) Disable all of outside loads. 2. Inspecting diagnosis codes (reading with 'Engine Diagnostic Program') (1) To Use check mode, according to the instruction of the 'Engine Diagnostic Program', press [Utility]  select [Check mode]. (2) According to the instruction of the 'Engine Diagnostic Program' screen, press [Trouble code] and check the diagnosis code. 3. Deleting diagnosis code memory (using 'Engine Diagnostic Program') (1) According to the instruction of the 'Engine Diagnostic Program' screen, press [Trouble code]  press [Clear], to delete the diagnosis code. SST 09111-36760-71 (09991-70201) Caution: • If it cannot be deleted, turn the ignition key switch OFF and then delete it again. • Do not delete diagnosis codes with 'Engine Diagnostic Program' before making diagnosis and checking symptoms. 4. Deleting diagnosis codes (by removing fuse) (1) Remove the EFI2 fuse (10 A), and in 15 seconds or more connect the fuse. Caution: • Be sure to delete diagnosis code memory after inspecting and repairing the ECD system. Then, check that normal codes are output. • Do not delete diagnosis codes by clearing the battery (removing the fuse) before making diagnosis and checking symptoms. 5. Checking diagnosis results (using 'Engine Diagnostic Program') SST 09111-36760-71 (09991-70201) Note: After repairing the faulty system with the output diagnosis code or when performing a recreation test after deleting the diagnosis code, check output diagnosis codes. (1) Use 'Engine Diagnostic Program' to delete the diagnosis code. (2) Perform a test for checking diagnosis results. (3) According to the instruction of the 'Engine Diagnostic Program' screen, press [Trouble code]. (4) Check diagnosis code results. 1 2 Engine room relay block EFI2 fuse 1KD_RM.book 13 ページ 2013年9月27日 金曜日 午後12時47分
  • 15. 1-14 FREEZE FRAME DATA/DIAGNOSIS DETAILED INFORMATION 1. Checking freeze frame data (reading with 'Engine Diagnostic Program') With 'Engine Diagnostic Program', according to the instruction of the screen, press [Trouble code]. Indicates existance of freeze frame data with a mark in [FED], press the mark. SST 09111-36760-71 (09991-70201) (1) Turn the ignition key switch ON. (2) Press [Trouble code]. Indicates existance of freeze frame data with a mark in [FED], press the mark. (3) In the screen displaying the diagnosis code, detected diagnosis codes appear. (4) Select a diagnosis code for which freeze frame data is checked. 2. Checking chronological freeze frame data (1) In the screen displaying freeze data, select an item for which chronological freeze frame data is checked. Note: • Chronological freeze frame data also includes ECU data recorded at the occurrence of a diagnosis code and around that point. • Chronological freeze frame data can be checked when press a mark in [FED], ' '. • For chronological freeze frame data, a total number of five points (including a diagnosis detection point, three points before detection, one point after detection) can be displayed. 3. List of freeze frame data DTC detection point Freeze frame data recording point 0.5 sec. 0.5 sec. 0.5 sec. 1 2 3 4 Item name Engine Speed Actual VN Position Calculate Load VN Position Sensor Out MAF VN Motor Duty Atmosphere Pressure VN Close Learn Value MAP VN Close Learn Status Coolant Temp Initial Engine Coolant Temp Intake Air Initial Intake Air Temp Engine Run Time Engine Start Time Starter Signal Engine Speed (Starter Off) Injection Volume Starter Count Pilot 1 Injection Period Electric Duty Feedback Value Pilot 2 Injection Period Intake Air Temp (Turbo) Main Injection Period Battery Voltage After Injection Period Engine Speed of Cyl #1 Pilot 1 Injection Timing Engine Speed of Cyl #2 Pilot 2 Injection Timing Engine Speed of Cyl #3 Main Injection Timing Engine Speed of Cyl #4 After Injection Timing Av Engine Speed of All Cyl 1KD_RM.book 14 ページ 2013年9月27日 金曜日 午後12時47分
  • 16. 1-15 INSPECTION OF IRREGULAR PROBLEMS 1. Inspecting irregular problems (this can be done only when 'Engine Diagnostic Program' is used) Note: Follow the procedure below to change the mode. This allows improvement of disconnection detection sensitivity and more reliable detection of irregular defects. (1) Delete diagnosis codes. (See page 1-13 for the procedure and notes.) (2) Set the check mode. (See page 1-13 for the procedure and notes.) (3) Perform a simulation (recreation) test. (See page 0-16 for the procedure and notes.) (4) Visually inspect the connector and each terminal, and inspect the connection condition. (See page 0-11 for the procedure and notes.) (5) Inspect the wire harness and connector for excessive force. (See page 0-13 for the procedure and notes.) (6) Use a cooling method for inspection. (See page 0-16 for the procedure and notes.) 2. Checking wire harness and connector instantaneous interruption Note: If a defective system is found based on an output diagnosis code at the inspection of diagnosis codes (check mode), its location should be pinpointed in the following way: (1) After reading the diagnosis code in the check mode, delete diagnosis code memory. (See page 1-13 for the procedure and notes.) (2) Select the check mode, and start the engine. (See page 1-13 for the procedure and notes.) (3) With the engine idling, shake the wire harness and the connector of the defective system where the diagnosis code was output at the inspection of diagnosis codes (check mode). (See page 0-16 for the procedure and notes.) (4) After the wire harness and the connector are shaken, when the engine check indicator turns on, the connection of them may be poor. Injector Memory Error Time after DTC Cleared Target Common Rail Pressure Warmup Cycle Cleared DTC Fuel Press TC and TE1 Fuel Temperature Isochronous Control Target Speed Target Pump SCV Current Isochronous Control Proportional Term Pump SCV Learning Value Isochronous Control Integral Term Accel Position Total Operation Hours Accel Sens. No.1 Volt % Total Number of Rotations Accel Sens. No.2 Volt % Total Injection Volume Target EGR Pos. Pre Glow Actual EGR Valve Pos. After Glow EGR Close Lrn. Val. Target Idle Engine Speed EGR Close Lrn. Status Adjustment Volume Mode Status Value after Confirmation EGR Operation Prohibit Target Booster Pressure Fuel Return Temp VN Turbo Command EGR Motor Duty #1 Item name 1KD_RM.book 15 ページ 2013年9月27日 金曜日 午後12時47分
  • 17. 1-16 WORK SUPPORT 1. List of work support steps When parts requiring initialization and writing have been replaced, initialize and write them by following the steps in the list below in numerical order. Note: The ID code represents 'Engine Diagnostic Program' saved in the engine control computer (injector compensation code). 2. Initializing the supply pump ASSY learned value Caution: Be sure to perform this precedure (initialization) after replacing the pump ASSY or the engine control computer. Note: If an error occurs during the initialization, do it again from <Procedure 1/4>. Work support item Replacement Reading and Saving the injector compensation code Initializing the supply pump ASSY leaned value Writing the injector compensation code Supply pump ASSY (1) Engine ASSY (1) Injector ASSY (1) Supply pump ASSY + engine ECU (1) (2) (3) Injector ASSY + engine ECU (1) (2) (3) Engine ASSY + engine ECU (1) (2) (3) Engine ECU (with old data) (1) (2) (3) Engine ECU (without old data) (1) (2) <Procedure 1/4> Select [Supply Pump Initialization] Initialization Cancel <Procedure 2/4> Press [Next] to proceed <Procedure 3/4> Check the initial conditions, then press [Next] <Procedure 4/4> Supply Pump Initialization is complete, press [Exit] 1KD_RM.book 16 ページ 2013年9月27日 金曜日 午後12時47分
  • 18. 1-17 (1) Turn the ignition key switch ON. According to the instruction of the 'Engine Diagnostic Program', press [Utility]. Caution: Do not start the engine. (2) <Procedure 1/4> Select [Supplt Pump Initialization], then press [Select]. (3) <Procedure 2/4> Press [Next] to proceed. (4) <Procedure 3/4> After check the initial conditions, then press [Next]. Caution: Preform this procedure, the ignition key switch turned on and the engine stopped. 1KD_RM.book 17 ページ 2013年9月27日 金曜日 午後12時47分
  • 19. 1-18 (5) <Procedure 4/4> Supply Pump Initialization is complete, press [Exit]. (6) Start up the engine for warm up. Caution: Do not perform racing immediately after the engine is started. Note: • If the Engine does not start, do it again <procedure 1/4>. • The engine warm-up state shall be acondition water temperature is 60 °C (140 °F) or more and fuel temperature is 20 °C (68 °F) or more. (a) To check water temperature, in the 'Engine Diagnostic Program' select [Data monitor] and monitor [Coolant Temp] Reference 60 °C (140 °F) or more (b) To check fuel temperature, in the 'Engine Diagnostic Program' Select [Data monitor] and monitor [Fuel Temperature] Reference 20 °C (68 °F) or more • When fuel temperature does not increase due toan environment to be measured, increase engine speed litlle by little until it reaches NMR (No load Maximum Revolution), make it the steady state, and then increase the temperature. Do not perform racing rapidly. (7) Run at idle for one minute or more in the state after engine warm-up. (8) The initializatin is now completed. 1KD_RM.book 18 ページ 2013年9月27日 金曜日 午後12時47分
  • 20. 1-19 3. Reading and Saving the injector compensation code In this procedure, read codes (injector compensation codes) from the engine control computer, and save compensation codes to the 'Engine Diagnostic Program'. Note: • Due to the defective engine control computer or wire harness, or poor connection of the diagnostic connector, a writing abnormally may occur. Inspect and check the connection of the wire harness or the diagnostic connector. When they are normal, the engine control computer may be defective. • For replacement ECU, need to write the compensation codes of each cylinder. Use this saving compensation codes function to avoid error, writing incorrect compensation code, install another cylinder No. • This saving function can save one latest data of each cylinder. • If using saved data, confirm the saved compensation code and cylinder number, and compensation code of the top of the injector ASSY are right. <Procedure 1/6> Select [Injector compensation] Cancel Read Compensation Code In case of reading another cylinder compensation code Save Replace <Procedure 2/6> <Procedure 3/6> Select a function [Read Compensation Code] <Procedure 4/6> Select a Cylinder number <Procedure 5/6> Appears Cylinder No and Compensation Code <Procedure 6/6> Press [Replace] or [Save] (In case of there is no compensation code) (In case of there is previous compensation code) Next 1KD_RM.book 19 ページ 2013年9月27日 金曜日 午後12時47分
  • 21. 1-20 (1) Turn the ignition key switch ON. According to the instruction of the 'Engine Diagnostic Program', press [Utility]. Caution: Do not start the engine. (2) <Procedure 1/6> Select [Injector Compensation], then press [Select]. (3) <Procedure 2/6> Press [Next] to proceed, read <NOTICE> message, then press [Next]. (4) <Procedure 3/6> Select a function [Read Compensation Code], then press [Next]. 1KD_RM.book 20 ページ 2013年9月27日 金曜日 午後12時47分
  • 22. 1-21 (5) <Procedure 4/6> Select a Cylinder number from No.1 to 4, then press [Next]. (6) <Procedure 5/6> Note: Appears selected cylinder No. and compensation code. To save the compensation code, press [Save]. If there is previous saved data, and need to save new compensation data, press [Replace]. If there is no previous saved data, and need to save new compensation data, press [Save]. Caution: This saving function can save one latest data of each cylinder. Confirm the cylinder number, and saved date and time to use this saved data, in case of writing a compensation code to replaced engine control computer. If you need all cylinder compensation codes, repeat this procedure same times as cilynder numbers. 1KD_RM.book 21 ページ 2013年9月27日 金曜日 午後12時47分
  • 23. 1-22 (7) <Procedure 6/6> To read another Cylinder’s injector compensation code, press [Next] and repeat this procedure from <Procedure 4/6>. To exit this function, press [Cancel]. 1KD_RM.book 22 ページ 2013年9月27日 金曜日 午後12時47分
  • 24. 1-23 4. Writing the injector compensation code In this procedure, write codes (injector compensation codes) to the engine control computer. • Use saved compensation codes in the 'Engine Diagnostic Program'. • Input manual compensation codes. Note: • Due to the defective engine control computer or wire harness, or poor connection of the diagnostic connector, a writing abnormally may occur. Inspect and check the connection of the wire harness or the diagnostic connector. When they are normal, the engine control computer may be defective. • In case of replacement ECU, need to write the compensation codes of each cylinder. Use saved codes or input manually. If using saved data, confirm the saved compensation code and cylinder number, and compensation code of the top of the injector ASSY are right. Program can save one latest data of each cylinder. • In case of replacement ECU, injector ASSY, or engine, need to write the compensation codes of each cylinder. Input the compensation codes manually. Confirm the cylinder number and compensation code of the top of the injector ASSY are right. <Procedure 1/6> Select [Injector compensation] Cancel Replacement 1)engine control computer Use saved compensation codes Input manual compensation codes <Procedure 2/6> <Procedure 3/6> Select a function [Set Compensation Code] <Procedure 4/6> Select a Cylinder number <Procedure 5-a/6> Press [Open] <Procedure 6/6> Writing is complete Writing compensation codes <Procedure 5-b/6> Press [Input] Writing compensation codes Replacement 1)engine control computer 2)injector ASSY 3)engine 1KD_RM.book 23 ページ 2013年9月27日 金曜日 午後12時47分
  • 25. 1-24 Note: If you use the directly read the compensation code, read the code (30-digit alphanumerical characters) punched on the head of the injector ASSY. (1) Turn the ignition key switch ON. According to the instruction of the 'Engine Diagnostic Program', press [Utility]. Caution: Do not start the engine. (2) Select [Supplt Pump Initialization], then press [Select]. (3) <Procedure 1/6> Select [Injector Compensation], then press [Select]. (4) <Procedure 2/6> Press [Next] to proceed, read <NOTICE> message, then press [Next]. Code Injector ASSY 1KD_RM.book 24 ページ 2013年9月27日 金曜日 午後12時47分
  • 26. 1-25 (5) <Procedure 3/6> Select a function [Set Compensation Code], then press [Next]. (6) <Procedure 4/6> Select a Cylinder number from No.1 to 4, then press [Next]. Use a saved compensation code: go to (8) Input a manual compensation code: go to (9) (7) <Procedure 5-a/6> Use a saved compensation code, press [Open]  Confirm [Cylinder Number] and [Saved Date], then press [Open]  press [Next] to write the saved data. Caution: Confirm the saved compensation code, cylinder number, and compensation code of the top of the injector ASSY are right. Program can save one latest data of each cylinder. If the compensation code writing error occurs, write again.  go to (9) 1KD_RM.book 25 ページ 2013年9月27日 金曜日 午後12時47分
  • 27. 1-26 (8) <Procedure 5-b/6> Input a manual compensation code, press [Input]  Using a key to input the code, then press [OK]  press [Next] to write the data. Caution: Confirm the cylinder number, compensation code of the top of the injector ASSY, input compensation code are right. If the compensation code writing error occurs, write again. If the inputted code is incorrect, 'Error Injector Compensation' occurs, input compensation code correctly.  go to (9) (9) <Procedure 6/6> Injector compensation writing is complete. Press [Next] to continue writing code of the other cylinder, press [Cancel] to exit this function. (10) After completing writing, delete the diagnosis code. 1KD_RM.book 26 ページ 2013年9月27日 金曜日 午後12時47分
  • 28. 1-27 5. Fuel System inspection Perform this procedure, to air bleeding after fuel system parts replacement, or to check fuel system malfunction. Note: • Engine revolution rises, confirm the vehicle not moving. • Operate acceleration pedal according to the 'Engine Diagnostic Program' screen. <Procedure 1/8> Select [Fuel System Check] Cancel <Procedure 2/8> Start the engine <Procedure 3/8> Warm up the engine <Procedure 4/8> Rise the engine revolution over 1400rpm <Procedure 5/8> Check completed <Procedure 6/8> Save data (in case of fuel system malfunction check) <Procedure 7/8> Repeat 5 times the procedure <Procedure 8-a/8> Keep Idling <Procedure 8-b/8> Data analysis Checking the Fuel System Fuel system parts replacement Fuel system malfunction check 1KD_RM.book 27 ページ 2013年9月27日 金曜日 午後12時47分
  • 29. 1-28 (1) Turn the ignition key switch ON. According to the instruction of 'Engine Diagnostic Program', press [Utility]. (2) <Procedure 1/8> Select [Fuel System Check], then press [Select] Until the water temperature becomes 70degC (158degF) or higher, can not proceed. (3) <Procedure 2/8> Read the message, and start the engine, keep idling, then press [Next] (4) <Procedure 3/8> Warm up the engine. The water temperature (engine coolant temperature) is 70 °C (158 °F) or higher, then press [Next]. Note: Until the water temperature becomes 70 °C (158 °F) or higher, can not proceed. 1KD_RM.book 28 ページ 2013年9月27日 金曜日 午後12時47分
  • 30. 1-29 (5) <Procedure 4/8> Open the acceleration pedal, rise the engine revolution over 1400rpm, then press [Next]. Fuel system check starts automatically, needs 15sec, check is completed. Caution: Open the acceleration pedal until the check is completed. Note: Fuel system check can proceed under the condition that the engine revolution is over 1400rpm. If the condition is not satisfied, the check stops. The engine revolution automatically keep 1400rpm while the check is proceeding. The combustion noise becomes louder while the check is proceeding, this phenomena is not malfunction. (6) <Procedure 5/8> Fuel System Check is completed, close the acceleration pedal, press [Exit]. (7) <Procedure 6/8> In case of fuel system malfunction check, press [Save]. Input the file name if necessary. (8) <Procedure 7/8> Repeat 5 times from <Procedure 1/8>. Fuel system parts replacement: go to (9) Fuel system malfunction check: go to (10) (9) <Procedure 8-a/8> Keep idling over 3min. (10) <Procedure 8-b/8> At <Procedure 1/8> screen, press [Proj info]. Select the saved data in 'Fuel System Check' folder, in Individual data list window. Display and confirm the graph from saved data. 1KD_RM.book 29 ページ 2013年9月27日 金曜日 午後12時47分
  • 31. 1-30 CIRCUIT DIAGRAM Ignition switch Glow plug Turbo charger S/A Starter Accelerator position sensor Battery GLOW GLOW GREL AM1 IGSW STA ST STA EFI2 EFI BATT VNM+ VNM- EDU VNVC MAIN VNA VNE2 +B2 +B MREL VCPA VPA EPA VCP2 VPA2 EPA2 A B Parking brake switch ECU-IG Neutral start relay ST T/C shift switch MAIN 1KD_RM.book 30 ページ 2013年9月27日 金曜日 午後12時47分
  • 32. 1-31 Fuel pressure sensor Suction control valve ASSY Injector driver Injector ASSY (No.1) Injector ASSY (No.2) Injector ASSY (No.3) Injector ASSY (No.4) Intake air flow meter Fuel filter pool switch Crank position sensor Crank position sensor No.2 Electric EGR control valve A B EDU IJ1+ IJ1- IJ2- IJ2+ IJ3- IJ3+ IJ4- IJ4+ GND +B #10 #20 #30 #40 INJF VCS1 PCR1 E2S1 PCV+ PCV- EGM+ EGM- VCEG EGRA EEGL NE+ NE- G+ G- IREL #1 #3 #2 INJ1 #4 E2G VG THA ETHA P 1KD_RM.book 31 ページ 2013年9月27日 金曜日 午後12時47分
  • 33. 1-32 Inlet air temperature sensor Water temperature sensor Fuel filter clogging switch Alternator Fuel temperature sensor Diesel turbo pressure sensor Combination meter ASSY SAS/OPS controller Atmospheric pressure sensor THF ALT ETHF CAN+ FPSW PIM VCPM EPIM EC CAN- THIA ETHI THW ETHW W GIND THWO W3 TC CANH CANL E02 E01 E1 ME01 OBD Diagnostic connector TC E 1KD_RM.book 32 ページ 2013年9月27日 金曜日 午後12時47分
  • 34. 1-33 ECU TERMINAL LAYOUT Reference Terminal number [Terminal symbol] Input Output Measurement condition Reference value B53 - B56 [VPA - EPA] Input Accelerator fully closed 0.5 to 1.1 V Accelerator fully opened 2.6 to 4.5 V B54 - B58 [VPA2 - EPA2] Input Accelerator fully closed 1.2 to 2.0 V Accelerator fully opened 3.4 to 5.0 V B43 - A109 [STA - E1] Input During cranking 6 V or more B32 [EC] - Engine ground Ground Always Less than 1 Ω B12 - A109 [W - E1] Output When the engine check indicator turns on (Ignition key switch ON) 0 to 3 V During idling (When the engine check indicator does not turn on) 11 to 14 V A B A B 1 2 3 20 21 22 4 5 6 12 13 14 23 24 25 7 8 9 15 16 17 26 27 28 11 10 18 19 29 30 4 5 6 7 8 9 11 10 12 13 14 15 16 17 18 19 1 2 3 24 25 26 27 28 29 30 20 21 22 23 55 37 36 35 34 33 32 31 53 52 51 50 49 48 47 54 39 38 61 60 59 58 57 56 63 62 40 41 42 43 44 45 46 31 32 33 50 51 52 34 35 36 42 43 44 53 54 55 37 38 39 45 46 47 56 57 58 41 40 48 49 59 60 67 68 69 70 71 72 74 73 75 76 77 78 79 80 64 65 66 87 88 89 90 91 92 93 118 100 99 98 97 96 95 94 116 115 114 113 112 111 110 117 102101 124123122121120119 126125 103 81 82 83 84 85 86 104 105 106 107 108 109 #4 #3 #2 #1 INJ1 ALT P GREL FPSW CAN+ CAN- E01 E02 VNM- VNM+ PCV+ VCS1 THIA ETHI E2S1 THF ETHF PCR1 THW ETHW VG THA ETHA E2G VCEG VNE2 EPIM PIM VNVC VNA VCPM EGRA EEGL PCV- NE+ NE- G+ G- E1 EGM+ EGM- ME01 +B EC BATT +B2 EPA MREL VCPA IREL VPA2 STA VPA TC IGSW W3 CANH CANL W EPA2 VCP2 THWO GIND 1KD_RM.book 33 ページ 2013年9月27日 金曜日 午後12時47分
  • 35. 1-34 B2 - A109 [BATT - E1] Input Always 11 to 14 V B1 - A109 [+B - E1] Input Engine stop Ignition key switch ON 11 to 14 V B20 - A109 [+B2 - E1] Input Engine stop Ignition key switch ON 11 to 14 V B55 - B56 [VCPA - EPA] Output Engine stop Ignition key switch ON 4.5 to 5.5 V B57 - B58 [VCP2 - EPA2] Output Engine stop Ignition key switch ON 4.5 to 5.5 V B45 - A109 [MREL - E1] Output Engine stop Ignition key switch ON 11 to 14 V Engine stop 10 seconds or more elapsed after igni- tion key switch turns off 0 to 1.5 V B44 - A109 [IREL - E1] Output During idling 0 to 1.5 V B38 - A109 [THWO - E1] Output During idling Pulse generation (Waveform 1) B30 - A109 [GIND - E1] Output Ignition key switch ON, While the glow indicator turns on 0 to 3 V After warm-up, during idling 11 to 14 V B26 - A109 [TC - E1] Input Ignition key switch ON 11 to 14 V Short-circuit between the terminals TC and E of the diagnostic connector 0 to 1.5 V B25 - A109 [IGSW - E1] Input Engine stop Ignition key switch ON 11 to 14 V B7 - A109 [CANH - E1] Input and output Engine stop Ignition key switch ON Pulse generation (Waveform 2) B6 - A109 [CANL - E1] Input and output Engine stop Ignition key switch ON Pulse generation (Waveform 3) A113 - A90 [THIA - ETHI] Input Intake temperature 0 to 80 °C (32 to 176 °F) (during warm-up) 0.5 to 3.4 V A112 - A89 [THF - ETHF] Input Ignition key switch ON (when cool) 0.5 to 3.4 V Fuel temperature 20 °C (68 °F) 2.0 to 2.7 V A111 - A88 [THW - ETHW] Input Cooling water temperature 60 to 120 °C (140 to 248 °F) (during warm-up) 0.2 to 1.0 V A110 - A87 [THA - ETHA] Input Intake temperature 0 to 80 °C (32 to 176 °F) (during warm-up) 0.5 to 3.4 V A67 [E2S1] - Engine ground Ground Always Less than 1 Ω A68 - A67 [VCS1 - E2S1] Output Engine stop Ignition key switch ON 4.5 to 5.5 V A66 - A67 [PCR1 - E2S1] Input After warm-up, during idling 1.7 to 2.2 V A65 - A64 [VG - E2G] Input After warm-up, during idling Pulse generation A64 [E2G] - Engine ground Ground Always Less than 1 Ω A51 - A109 [INJ1 - E1] Input After warm-up, during racing Pulse generation (Waveform 4) A50 - A109 [#1 - E1] Output After warm-up, during idling Pulse generation (Waveform 5) A49 - A109 [#2 - E1] Output After warm-up, during idling Pulse generation (Waveform 5) A48 - A109 [#3 - E1] Output After warm-up, during idling Pulse generation (Waveform 5) A47 - A109 [#4 - E1] Output After warm-up, during idling Pulse generation (Waveform 5) Terminal number [Terminal symbol] Input Output Measurement condition Reference value 1KD_RM.book 34 ページ 2013年9月27日 金曜日 午後12時47分
  • 36. 1-35 Terminal number [Terminal symbol] Input Output Measurement condition Reference value B2 - A109 [BATT - E1] Input Always 11 to 14 V B1 - A109 [+B - E1] Input Engine stop Ignition key switch ON 11 to 14 V B20 - A109 [+B2 - E1] Input Engine stop Ignition key switch ON 11 to 14 V B55 - B56 [VCPA - EPA] Output Engine stop Ignition key switch ON 4.5 to 5.5 V B57 - B58 [VCP2 - EPA2] Output Engine stop Ignition key switch ON 4.5 to 5.5 V B45 - A109 [MREL - E1] Output Engine stop Ignition key switch ON 11 to 14 V Engine stop 10 seconds or more elapsed after ignition key switch turns off 0 to 1.5 V B44 - A109 [IREL - E1] Output During idling 0 to 1.5 V B38 - A109 [THWO - E1] Output During idling Pulse Generation (Waveform 1) B30 - A109 [GIND - E1] Output Ignition key switch ON, While the glow indicator turns on 0 to 3 V After warm-up, during idling 11 to 14 V B26 - A109 [TC - E1] Input Ignition key switch ON 11 to 14 V Short-circuit between the terminals TC and E of the diagnostic connector 0 to 1.5 V B25 - A109 [IGSW - E1] Input Engine stop Ignition key switch ON 11 to 14 V B7 - A109 [CANH - E1] Input and output Engine stop Ignition key switch ON Pulse generation (Waveform 2) B6 - A109 [CANL - E1] Input and output Engine stop Ignition key switch ON Pulse generation (Waveform 3) A113 - A90 [THIA - ETHI] Input Intake temperature 0 to 80 °C (32 to 176 °F) 0.5 to 3.4 V A112 - A89 [THF - ETHF] Input Ignition key switch ON (when cool) 0.5 to 3.4 V Fuel temperature 20 °C (68 °F) 2.0 to 2.7 V A111 - A88 [THW - ETHW] Input Cooling water temperature 60 to 120 °C (140 to 248 °F) 0.2 to 1.0 V A110 - A87 [THA - ETHA] Input Intake temperature 0 to 80 °C (32 to 176 °F) 0.5 to 3.4 V A67 [E2S1] - Engine ground Ground Always Less than 1 Ω A68 - A67 [VCS1 - E2S1] Output Engine stop Ignition key switch ON 4.5 to 5.5 V A66 - A67 [PCR1 - E2S1] Input After warm-up, during idling 1.7 to 2.2 V A65 - A64 [VG - E2G] Input After warm-up, during idling Pulse Generation A64 [E2G] - Engine ground Ground Always Less than 1 Ω A51 - A109 [INJ1 - E1] Input After warm-up, during racing Pulse Generation (Waveform 4) A50 - A109 [#1 - E1] Output After warm-up, during idling Pulse Generation (Waveform 5) A49 - A109 [#2 - E1] Output After warm-up, during idling Pulse generation (Waveform 5) A48 - A109 [#3 - E1] Output After warm-up, during idling Pulse generation (Waveform 5) A47 - A109 [#4 - E1] Output After warm-up, during idling Pulse generation (Waveform 5)
  • 37. 1-36 1. Oscilloscope waveform (1) Waveform 1 Note: Depending on cooling water temperature, A changes. (2) Waveform 2 (3) Waveform 3 (4) Waveform 4 Note: As the engine speed increases, the waveform cycle gets shorter. GND A A Item Description Measurement terminals THWO - E1 Gauge set 5 V/DIV, 100 ms/DIV Conditions During idling Water temperature A 30 °C (86 °F) 16 ms 90 °C (194 °F) 278.5 ms 120 °C (248 °F) or more 385 ms GND Item Description Measurement terminals CANH - E1 CAN+ - E1 Gauge set 1 V/DIV, 10 ms/DIV Conditions Engine stop Ignition key switch ON GND Item Description Measurement terminals CANL - E1 CAN- - E1 Gauge set 1 V/DIV, 10 ms/DIV Conditions Engine stop Ignition key switch ON GND Item Description Measurement terminals CH1: INJ1 - E1 Gauge set 2 V/DIV, 1 ms/DIV Conditions After warm-up, during racing 1KD_RM.book 36 ページ 2013年9月27日 金曜日 午後12時47分
  • 38. 1-37 (5) Waveform 5 Note: As the engine speed increases, the waveform cycle gets shorter. (6) Waveform 6 (7) Waveform 7 Note: • As the engine speed increases, each amplitude becomes larger. • As the engine speed increases, the waveform cycle gets shorter. (8) Waveform 8 GND GND GND GND CH1 CH3 CH4 CH2 Item Description Measurement terminals CH1: #1 - E1 CH2: #2 - E1 CH3: #3 - E1 CH4: #4 - E1 Gauge set 5 V/DIV, 20 ms/DIV Conditions After warm-up, during idling GND Item Description Measurement terminals ALT - E1 Gauge set 5 V/DIV, 5 ms/DIV Conditions During idling GND GND CH1 CH2 Item Description Measurement terminals CH1: NE+ - NE- CH2: G+ - G- Gauge set 5 V/DIV, 20 ms/DIV Conditions After warm-up, during idling GND GND CH1 CH2 Item Description Measurement terminals CH1: PCV+ - E1 CH2: PCV- - E1 Gauge set CH1: 10 V/DIV, 5 ms/DIV CH2: 500 mv/DIV, 5 ms/DIV Conditions After warm-up, during idling 1KD_RM.book 37 ページ 2013年9月27日 金曜日 午後12時47分
  • 39. 1-38 (9) Waveform 9 Note: The waveform depends on operations of the turbo charger S/ A. (10) Waveform 10 Note: The waveform depends on operations of the turbo charger S/ A. Item Description Measurement terminals VNM+ - E1 Gauge set 5 V/DIV, 20 ms/DIV Conditions After warm-up, during idling Item Description Measurement terminals VNM- - E1 Gauge set 5 V/DIV, 50 ms/DIV Conditions After warm-up, during idling 1KD_RM.book 38 ページ 2013年9月27日 金曜日 午後12時47分
  • 40. 1-39 ECU DATA MONITOR/ACTIVE TEST 1. List of ECU data monitor (1) With SST, according to the instruction of the screen, display [Data monitor] to inspect computer data. Note: • To check the standard, unless otherwise specified, completely warm up the engine, disable all of outside loads, select the N range, and power off each accessory. • Results of the inspection in the actual machine are reference values, so actual values may be different depending on regions or weather. SST 09111-36760-71(09991-70201) Item name Description/ Display range Reference Remarks Engine Speed • Indicates engine speed. • Display range: 0 to 6000 r/min • 50 to 400 r/min: During cranking • 700 to 800 r/min: After engine warm- up, during idling • It displays a value output from the crank position sensor No.2. • If the crank position sensor No.2 does not oper- ate properly, the engine speed becomes about 0 r/min or is remarkably different from the actual engine speed. Calculate Load • Indicates engine load. • Display range: 0 to 100% 13 to 25%: After engine warm-up, during idling (Disable all of outside loads, N range) • It displays a value calculated by the engine con- trol computer. • Engine load value = (Actual fuel injection amount/Maximum fuel injec- tion amount in the current engine speed) x 100 MAF • Indicates intake air quantity. • Display range: 0 to 655.35 g/sec (0 to 86.69 lb/min) • 16 to 24 g/sec (2.12 to 3.17 lb/min): After engine warm- up, during idling • 40 to 65 g/sec (5.29 to 8.60 lb/min): For engine speed NMR (No Load Max- imum Revolution) Note: It changes depend- ing on the amount of EGR. • It displays a value output from the intake air flow meter S/A. • Based on intake air quantity, the engine control computer controls fuel injection amount, injection timing, EGR, and others. • When intake air quantity is always about 0 g/sec (0 lb/min): - The power circuit of the intake air flow meter S/ A is disconnected. - The VG circuit is disconnected or short-cir- cuited. - The EVG circuit is disconnected. Symptoms when outside the reference: Rough idling Atmosphere Pressure • Atmospheric pres- sure value. • Display range: 0 to 250 kPa Actual atmospheric pressure • With ignition key switch turned on, when a differ- ence between a value of the atmospheric pres- sure sensor and that of the intake manifold pressure sensor is 10 kPa or more, either sensor has an abnormality. • With ignition key switch turned on, when atmo- spheric pressure is 0 kPa or 140 kPa, the sensor circuit is abnormal. • Standard atmospheric pressure: 101 kPa • Atmospheric pressure decreases by 1 kPa with each lifting of 100 m (328 ft). This changes depending on weather (high or low atmospheric pressure). • The atmospheric pressure sensor is contained in the engine control computer. 1KD_RM.book 39 ページ 2013年9月27日 金曜日 午後12時47分
  • 41. 1-40 ECU DATA MONITOR/ACTIVE TEST 1. List of ECU data monitor (1) With 'Engine Diagnostic Program', according to the instruction of the screen, display [Data monitor] to inspect computer data. NOTICE: • To check the reference, unless otherwise specified, completely warm up the engine, disable all of outside loads, select the N range, and power off each accessory. • Results of the inspection in the actual machine are reference values, so actual values may be different depending on regions or weather. SST: 09240-36770-71 Item Name Description/ Display Range Reference Remarks Engine Speed • Indicates engine speed • Display range: 0 to 6000 rpm • 50 to 400 rpm: During cranking • Refer to repair manual of the vehicle: After engine warm-up, during idling • It displays a value output from the crank position sensor No. 2. • If the crank position sensor No. 2 does not operate properly, the engine speed becomes about 0 rpm or is remarkably different from the actual engine speed. Calculate Load • Indicates engine load. • Display range: 0 to 100% 10 to 30%: After engine warm-up, during idling (disable all of outside loads, N range) • It displays a value calculated by the engine control computer. • Engine load value = (Actual fuel injection amount/Maximum fuel injection amount in the current engine speed) x 100 MAF • Indicates intake air quantity. • Display range: 0 to 655.35 g/sec (0 to 86.69 lb/min) • 6 to 25 g/sec (0.79 to 3.17 lb/min): After engine warm- up, during idling • 30 to 80 g/sec (3.96 to 10.6 lb/min): For engine speed NMR NOTE: It changes depending on the amount of EGR. • It displays a value output from the intake air flow meter S/A. • Based on intake air quantity, the engine control computer controls fuel injection amount, injection timing, EGR, and others. • When intake air quantity is always about 0 g/sec (0 lb/min): -The power circuit of the intake air flow meter S/A is disconnected. -The VG circuit is disconnected or short-circuited. -The EVG circuit is disconnected. Symptoms when outside the reference: -Rough Idling Atmosphere Pressure • Atmospheric pressure value. • Display range: 0 to 255 kPa Actual atmospheric pressure • With ignition key switch turned on, when a difference between a value of the atmospheric pressure sensor and that of the intake manifold pressure sensor is 10kPa or more, either sensor has an abnormality. • With ignition key switch turned on, when atmospheric pressure is 0kPa or 140 kPa, the sensor circuit is abnormal. • Standard atmospheric pressure: 101 kPa • Atmospheric pressure decreases by 1 kPa with each lifting of 100 m (328 ft). This changes depending on weather (high or low atmospheric pressure). • The atmospheric pressure sensor is contained in the engine control computer.
  • 42. 1-41 Item name Description/ Display range Reference Remarks MAP • Indicates absolute pressure of the internal intake manifold. • Display range: 0 to 255 kPa • 90 to 110 kPa (depending on atmospheric pressure): During idling • 115 to 160 kPa: For engine speed NMR • With ignition key switch turned on or during idling, intake manifold pressure and atmospheric pressure are almost the same (standard atmospheric pressure = 101 kPa). • With the accelerator fully opened, when intake manifold pressure is 20 kPa lower than target supercharging pressure for five seconds or more, you may feel insufficient output. • It displays a value output from the diesel turbo pressure sensor. Symptoms when outside the reference: Insufficient output Coolant Temp • Indicates engine cooling water tem- perature. • Display range: -40 to 140 °C (-40 to 284 °F) 70 to 90 °C (158 to 194 °F): After engine warm-up • When engine cooling water temperature is -40 °C (-40 °F) or 140 °C (284 °F), the sensor circuit is disconnected or short-circuited. • After it is left for a long time, engine cooling water temperature, intake air temperature, and ambient temperature become almost the same. • It displays a value output from the water temper- ature sensor. Symptoms when outside the reference: Difficulty in starting the engine when cool, rough idling, black smoke, insufficient output Intake Air • Indicates intake air temperature. • Display range: -40 to 140 °C (-40 to 284 °F) A value equal to tem- perature in the posi- tion where the intake air flow meter S/A is mounted • After it is left for a long time, engine cooling water temperature, intake air temperature, and ambient temperature become almost the same. • When intake air temperature is -40 °C (-40 °F) or 140 °C (284 °F), the sensor circuit is disconnected or short-circuited. • It displays a value output from the inlet air tem- perature sensor contained in the intake air flow meter S/A. Engine Run Time • Indicates rotating time after the engine starts. • Display range: 0 to 65535 sec Rotating time after the engine starts • Indicates elapsed time after the engine starts. Starter Signal • Indicates starter signals. • Display range: ON/ OFF ON: During cranking Ignition switch (STA) output: • ON: Indicates that the engine is cranking. • OFF: Indicates that the engine is not cranking Although STA is turned off, the starter continues to operate. The STA signal abnormality (P0617) is stored. Injection Volume • Indicates fuel injec- tion amount. • Display range: 0 to 1279.98 mm3/ st 5 to 15 mm3/st: During idling (Disable all of outside loads, N range) • It displays fuel injection amount for each combus- tion. • For the injector ASSY clogging, low fuel quality, fuel filter element clogging, or increased engine friction, fuel injection amount will increase. • For abnormalities such as low intake manifold pressure or a small quantity of intake air, fuel injection amount is limited, which causes insuffi- cient output. • It displays a value calculated by the engine con- trol computer.
  • 43. 1-42 Item Name Description/Display Range Reference Remarks Pilot 1 Injection Period  Indicates pilot 1 injection period.  Display range: 0 to 65535 µs 200 to 300 µs: During idling (water temperature is less than 60 °C (140 °F), disable all of outside loads, N range)  For symptoms such as knocking, poor drivability, or white smoke, check pilot 1 injection period. (with or without pilot injection)  It displays a value calculated by the engine control computer Symptoms when outside the reference: knocking, poor drivability, white smoke Pilot 2 Injection Period  Indicates pilot 2 injection period.  Display Range: 0 to 65535 µs 200 to 350 µs: During idling (complete warm-up, disable all of outside loads, N range)  For symptoms such as knocking, poor drivability, or white smoke, check pilot 2 injection period. (with or without pilot injection)  It displays a value calculated by the engine control computer. Symptoms when outside the reference: knocking, poor drivability, white smoke Main Injection Period  Indicates main injection period.  Display range: 0 to 65535 µs 300 to 600 µs: During idling (complete warm-up, disable all of outside loads, N range)  When fuel pressure becomes 15000 kPa or less, main injection period becomes 0 µs.  For engine hard starting, check main injection period. (with or without injection)  When P0093, P0627 or P062D is output, the engine stop request is output. In this case, main injection period becomes 0 µs. NOTICE: After the engine check indicator turns on, in about one minute the engine stops. Therefore, inspection cannot be performed with freeze frame data.  It displays a value calculated by the engine control computer After Injection Period  Indicates after injection period.  Display range: 0 to 65535 µs 0 to 400 µs: During idling (complete warm-up, disable all of outside loads, N range)  For symptoms such as black smoke and poor drivability, check after injection period. (with or without after injection)  It displays a value calculated by the engine control computer. Pilot 1 Injection Timing  Indicates pilot 1 injection timing.  Display range: -70 to 20 °CA -14 to -5 °CA: Water temperature is less than 60 °C (140 °F), during idling, and the machine is in the range of usual atmospheric pressure  It displays a value calculated by the engine control computer. Pilot 2 Injection Timing  Indicates pilot 2 injection timing.  Display range: -50 to 20 °CA -10 to -2 °CA: After engine warm-up, during idling, and the machine is in the range of usual atmospheric pressure.  It displays a value calculated by the engine control computer. Main Injection Timing  Indicates main injection timing.  Display range: -90 to 90 °CA -3 to 1 °CA: After engine warm-up, during idling, and the machine is in the range of usual atmospheric pressure.  For symptoms such as poor drivability, black smoke, or white smoke, check main injection timing.  It displays a value calculated by the engine control computer. After Injection Timing  Indicates after injection timing.  Display range: -10 to 50 °CA  It displays a value calculated by the engine control computer.
  • 44. 1-43
  • 45. 1-44 Item Name Description/ Display Range Reference Remarks Fuel Press  Indicates fuel pressure  Display Range: 0 to 655350 kpa 30000 to 50000kPa: during idling (complete warm-up, disable all of outside loads, N range)  Fuel pressure means the actual common rail fuel pressure.  Inspect fuel pressure, comparing to common rail target fuel pressure.  In the stable condition (during idling after warm- up) fuel pressure is within 5000 kPa of target value.  The engine control computer uses fuel pressure to perform feedback control of common rail target fuel pressure.  Fuel injection amount is determined based on injection timing and fuel pressure. Injection patterns are also selected based on fuel pressure.  Starting the engine requires a minimum of 25000 kPa fuel pressure. (note that when fuel pressure is about to reach its target, a delay is introduced even in the normal state)  When fuel pressure is lower than 25000 kPa, rough idling may occur.  When fuel pressure decreases from common rail target fuel pressure by 20000 kPa, output may be insufficient.  When the actual fuel pressure is 40000 kPa higher than common rail target fuel pressure, P1229 is output.  When fuel pressure is lower than a target value, insufficient output will occur without DTC output.  When fuel pressure is higher than 250000 kPa, DTC P0088 is output.  It displays a value output from the fuel pressure sensor (common rail assy) Symptoms when outside the reference: Difficulty starting the engine, poor drivability, insufficient output, knocking. Fuel Temperature  Indicates fuel temperature  Display range: - 40 to 215°C (-40 to 419°F) Actual fuel temperature  When the engine is completely cooled, fuel temperature is equal to ambient temperature.  It displays a value output from the fuel temperature sensor. Target Pump SCV Current  Indicates a target value of final pump current.  Display range: 0 to 8192 mA 1600 to 2000 mA: during idling (complete warm-up, disable all outside loads, N range)  It displays a calculated value by the engine control computer for target current for driving the suction control valve assy and controls a target value of solenoid current.  When high fuel pressure is required, a target value of solenoid current is higher.  Typically, a target value of solenoid current is in the range of 800 to 2500 mA.  When the target value remains a 3000mA or more, it indicates that the pump is defective. (such as a defect due to deposit)  If it is not in the standard, even when the pump operates actively, the actual fuel pressure does not match common rail fuel pressure. Symptoms when outside the reference: Difficulty in starting the engine, insufficient output, or rough idling.
  • 46. 1-45 Target EGR Pos. Indicates EGR valve target opening degree. Display range: 0 to 100% 0 to 90%: After engine warm-up, during idling (com- plete warm-up, dis- able all of outside loads, N range) • EGR valve fully opened: 100% • EGR valve fully closed: 0% • Inspect it comparing to the actual EGR opening degree #1. • EGR target opening degree displays a calculated value by the engine control computer based on sensor output values (such as the intake air flow meter S/A, inlet air temperature sensor (con- tained in the intake air flow meter S/A), diesel turbo pressure sensor). Symptoms when outside the reference: • When EGR target opening degree is not in the standard and near 0%, the intake air flow meter S/A may be abnormal, or an intake or exhaust system may get clogged. • When EGR target opening degree is not in the standard and near 100%, the EGR pipe may get clogged. Actual EGR Valve Pos. • Indicates EGR valve actual open- ing degree. • Display range: 0 to 100% 0 to 90%: After engine warm-up, during idling (complete warm-up, disable all of outside loads, N range) • EGR valve fully opened: 100% • EGR valve fully closed: 0% • It is effective to judge if the EGR valve is stuck. • Inspect it comparing to EGR target opening degree. • In the active test, check operations of the EGR valve. • When the EGR valve becomes abnormal around a certain temperature, refer to engine cooling water temperature and outside temperature which are reference in case of an abnormality. • The valve position displays a calculated value output from the EGR valve position sensor. Symptoms when outside the reference: • EGR valve stuck open: Hard starting (no engine stalling), black smoke, white smoke, insufficient output • EGR valve stuck close: Increase of turbo super- charging sound EGR Close Lrn. Val. • Indicates an EGR fully-closed posi- tion learned value. • Display range: 0 to 5.00 V 0 to 1 V • An EGR fully-closed position learned value is output voltage from the EGR valve position sen- sor. • When the EGR fully-closed position learned value becomes the upper or lower limit of the nor- mal range, foreign matter may be involved in the EGR valve. • The lower limit of the EGR fully-closed position learned value is 0 V, and the upper 1 V. When this value is fixed to either limit, the valve position sensor may be abnormal, or the valve position may be misplaced (with foreign matter). Item name Description/ Display range Reference Remarks 1KD_RM.book 45 ページ 2013年9月27日 金曜日 午後12時47分
  • 47. 1-46 EGR Close Lrn. Status • Indicates a state of EGR fully-closed position learning. • Display range: Completed/Not completed Completed • Completed: It means that fully-closed position learning is normally completed. • Not completed: It means that the learned fully- closed position may not in the correct range. • When it is not completed, foreign matter may be involved in the EGR valve. Note: After the battery cable is disconnected and then connected, when the ignition key switch is never turned off, learning may not be com- pleted. Results of inspection in the actual machine: Ignition key switch ON: Completed EGR Operation Prohibit • Indicates that oper- ations of EGR are prohibited. • Display range: OK/ NG OK: In the active test, EGR target opening degree bank 1 can be per- formed. • OK: In the active test, EGR target opening degree bank 1 can be performed. • NG: In the active test, EGR target opening degree bank 1 cannot be performed. Target Booster Pressure • Indicates target pressure of super- charging pressure. • Display range: 0 to 639.98 kPa - • Inspect it comparing to intake manifold pressure. • With the accelerator fully opened, when intake manifold pressure is 20 kPa lower than target supercharging pressure for five seconds or more, you may feel insufficient output. • It displays a value calculated by the engine con- trol computer. Boost Pressure Deviation • Indicates super- charging pressure deviation. • Display range: -320 to 320 kPa - It displays a difference between target supercharg- ing pressure and intake manifold pressure. VN Turbo Command • Indicates VN turbo motor target open- ing degree. • Display range: 0 to 100% 0 to 100% • VN turbo target opening degree is a command of the engine control computer. • 0%: The nozzle vane is fully opened. (The actuation rod is contracted) • 90% or more: The nozzle vane is fully closed(The actuation rod is extended) • When VN turbo target opening degree is large, the turbo operates effectively. • The command of the engine control computer controls nozzle vane opening degree. Actual VN Position • Indicates actual VNT opening degree. • Display range: 0 to 127.5% 0 to 100% • When movement of the nozzle vane becomes slow and it is stuck, a difference between this opening degree and VN turbo target opening degree is larger, and VN turbo output (duty) also becomes large. • VNT actual opening degree is controlled to suit VN turbo target opening degree. VN Position Sensor Out • Indicates VNT opening sensor output voltage. • Display range: 0 to 4.99 V 1 to 3 V: After engine warm-up, during idling It displays a value output from the nozzle vane opening degree sensor. VN Motor Duty • Indicates the VNT motor drive duty ratio. • Display range: 0 to 127.5% 2 to 88% When movement of the nozzle vane becomes slow, output (duty) increases to the direction of 100%. Item name Description/ Display range Reference Remarks 1KD_RM.book 46 ページ 2013年9月27日 金曜日 午後12時47分
  • 48. 1-47 VN Close Learn Value • Indicates a VNT fully-closed learn- ing voltage value. • Display range: 0 to 4.99 V 1.0 to 2.0 V - VN Close Learn Status • Indicates a VNT fully-closed posi- tion learning his- tory. • Display range: ON/ OFF ON When VN Close Learning is not completed, the performance of the machine may decrease. (low engine output) VN Turbo Operation Prohibit • Indicates that the VN turbo active test is prohibited. • Display range: Allowed/Prohibited Allowed: VN turbo opening degree can be per- formed in the active test. When it is prohibited, the engine control computer does not allow performing the active test for VN turbo opening degree. Initial Engine Coolant Temp • Indicates engine cooling water tem- perature at start- up. • Display range: -40 to 120 °C (-40 to 248 °F) Engine cooling water temperature at start- up • With freeze frame data, you can determine if an abnormality occurred at start-up when cool, or after the engine warm-up. • It displays a value output from the water temper- ature sensor at engine start-up. Initial Intake Air Temp • Indicates initial intake air tempera- ture. • Display range: -40 to 120 °C (-40 to 248 °F) Intake air tempera- ture at engine start-up It displays a value output from the intake air flow meter S/A (intake temperature sensor) at engine start-up. Engine Start Time • Indicates engine start time. • Display range: 0 to 267386 ms - It displays the time required by engine start-up. Engine Speed (Starter Off) • Indicates engine speed when the starter is turned off. • Display range: 0 to 1593 rpm - It displays engine speed immediately after the engine starts. Starter Count • Indicates how many times the starter has been turned on. • Display range: 0 to 255 - It displays how many times the starter has been turned on since ignition key switch was turned on. Electric Duty Feedback Value • Indicates an electri- cal load feedback value. • Display range: 0 to 39.8 mm3 /st 0 to 5 mm3 /st After electrical load is turned off and then on, ISC electrical load correction amount increases. Item name Description/ Display range Reference Remarks 1KD_RM.book 47 ページ 2013年9月27日 金曜日 午後12時47分
  • 49. 1-48 Intake Air Temp (Turbo) • Indicates intake air temperature after the inter cooler is passed. • Display range: -40 to 190 °C (-40 to 374 °F) During idling 70 °C (158 °F) or less • Indicates intake air temperature of the intake manifold (after the inter cooler ASSY is passed). • Intake air temperature after turbo charging is set to 170 °C (338 °F) while the fail safe function is operating. • When intake air temperature after turbo charging becomes high, turbo supercharging pressure is suppressed, which may cause insufficient output. • It displays a value output from the inlet air tem- perature sensor. Check Mode • Indicates the check mode state. • Display range: Check/Normal Check mode state: Check Check mode: A particular DTC can be easily detected at a high sensitivity. Battery Voltage • Indicates battery voltage. • Display range: 0 to 15 V 11 to 14 V: Ignition key switch ON When it is 11 V or less, characteristics of electronic parts will be changed. Symptoms when outside the reference: When it is 5 V or less, it is difficult to start the engine. Alternate Duty Ratio • Indicates the alter- nator power gener- ation duty ratio. • Display range: 0 to 100% - • It is used to output alternator power generation duty and to decide electrical load. • When injection amount during idling is larger than normal, it is used to determine if there are electri- cal load or other causes. • In the state where Alternate Duty Ratio is not high (low electrical load), when idling injection amount is large, injection amount of the injector ASSY may decrease, or engine friction may be large. • It is used to judge a power generation request state due to an abnormal electrical system. • Whether or not accessories (such as A/C or the heater) operate, when Alternate Duty Ratio is always the maximum value, an abnormality occurs in the electrical system (such as battery deterioration). • It displays a duty value from the ALT terminal. Engine Speed of Cyl #1 Engine Speed of Cyl #2 Engine Speed of Cyl #3 Engine Speed of Cyl #4 • Indicates cylinder engine speed. • Display range: 0 to 51199 rpm The engine speed of all cylinders are almost the same: Normal • It is output only when the engine speed is mea- sured for each cylinder in the active test. • Indicates engine speed for each cylinder during cranking. Example: - When compression of the No.1 cylinder is low, Engine Speed of Cyl #1 is about 300 rpm, Engine Speed of Cyl #2, #3, and #4 is about 200 rpm. - When compression of the No.2 cylinder is low, Engine Speed of Cyl #2 is about 300 rpm, Engine Speed of Cyl #1, #3, and #4 is about 200 rpm. - When compression of the No.3 cylinder is low, Engine Speed of Cyl #3 is about 300 rpm, Engine Speed of Cyl #1, #2, and #4 is about 200 rpm. - When compression of the No.4 cylinder is low, Engine Speed of Cyl #4 is about 300 rpm, Engine Speed of Cyl #1, #2, and #3 is about 200 rpm. Symptoms when outside the reference: When the engine speed of all cylinders is not the same, idling is not stable. Item name Description/ Display range Reference Remarks 1KD_RM.book 48 ページ 2013年9月27日 金曜日 午後12時47分
  • 50. 1-49 Av Engine Speed of All Cyl • Indicates the aver- age engine speed of all cylinders. • Display range: 0 to 51199 rpm - • It is output only when the engine speed is mea- sured for each cylinder in the active test. • Indicates the average engine speed of all cylin- ders during cranking. Time after DTC Cleared • Indicates elapsed time after DTC is deleted. • Display range: 0 to 65535 min Time after DTC is deleted It displays elapsed time after DTC is deleted (or shipped from the factory). Warm-up Cycle Cleared DTC • Indicates warm-up count after DTC is deleted. • Display range: 0 to 255 - • It displays engine warm-up count after DTC is deleted. • (Warm-up Cycle Cleared DTC of data list is deleted) - (Warm-up Cycle Cleared DTC of freeze frame data is deleted) = Warm-up count after an abnormality occurs TC and TE1 • Indicates the con- nection condition between TC and TE1 in the active test. • Display range: ON/ OFF - When the TE1/TC terminals are turned on in the active test, the system operates as if the TC termi- nal and E terminal of the diagnostic connector are connected. Isochronous Control Target Speed • Indicates the Isoch- ronous Control Tar- get Speed. • Display range: 0 to 12800 r/min 700 to 800 r/min: After engine warm-up, during idling It displays a value calculated by the engine control computer. Isochronous Control Proportional Term • Indicates the Isoch- ronous Control Proportional Term. • Display range: -50 to 120 mm3 /st - It displays a value calculated by the engine control computer. Isochronous Control Integral Term • Indicates the Isoch- ronous Control Integral Term. • Display range: -80 to 79.997 mm3 / st - It displays a value calculated by the engine control computer. Total Operation Hours • Indicates the Total Operation Hours. • Display range: 0 to 4500000000 sec - It displays a value calculated by the engine control computer. Total Number of Rotations • Indicates the Total Number of Rota- tions. • Display range: 0 to 4290000000 Rotations - It displays a value calculated by the engine control computer. Total Injection Volume • Indicates the Total Injection Volume. • Display range: 0 to 33554432 L (0 to 8864147 gal) - It displays a value calculated by the engine control computer. Item name Description/ Display range Reference Remarks 1KD_RM.book 49 ページ 2013年9月27日 金曜日 午後12時47分
  • 51. 1-50 Item name Description/ Display range Reference Remarks Av Engine Speed of All Cyl • Indicates the aver- age engine speed of all cylinders. • Display range: 0 to 51199 rpm - • It is output only when the engine speed is mea- sured for each cylinder in the active test. • Indicates the average engine speed of all cylin- ders during cranking. Time after DTC Cleared • Indicates elapsed time after DTC is deleted. • Display range: 0 to 65535 min Time after DTC is deleted • It displays elapsed time after DTC is deleted (or shipped from the factory). Warm-up Cycle Cleared DTC • Indicates warm-up count after DTC is deleted. • Display range: 0 to 255 - • It displays engine warm-up count after DTC is deleted. • (Warm-up Cycle Cleared DTC of data list is deleted) - (Warm-up Cycle Cleared DTC of freeze frame data is deleted) = Warm-up count after an abnormality occurs TC and TE1 • Indicates the con- nection condition between TC and TE1 in the active test. • Display range: ON/ OFF - • When the TE1/TC terminals are turned on in the active test, the system operates as if the TC ter- minal and E terminal of the diagnostic connector are connected. Isochronous Control Tar- get Speed • Indicates the Isoch- ronous Control Tar- get Speed. • Display range: 0 to 12800 r/min • It displays a target engine speed with the re- quest of vehicle is taken. Refer to repair manual of the vehicle After engine warm-up, during idling Isochronous Control Proportional Term • Indicates the Isoch- ronous Control Proportional Term. • Display range: -50 to 120 mm3/st - • It displays a value calculated by the engine con- trol computer. Isochronous Control Integral Term • Indicates the Isoch- ronous Control Integral Term. • Display range: -80 to 79.997 mm3/ st - • It displays a value calculated by the engine con- trol computer. Total Operation Hours • Indicates the Total Operation Hours. • Display range: 0 to 4500000000 sec - • It displays a value calculated by the engine con- trol computer. Total Number of Rotations • Indicates the Total Number of Rota- tions. • Display range: 0 to 4290000000 Rotations - • It displays a value calculated by the engine con- trol computer. Total Injection Volume • Indicates the Total Injection Volume. • Display range: 0 to 33554432 L (0 to 8864147 gal) - • It displays a value calculated by the engine con- trol computer.
  • 52. 1-51 Item name Description/ Display range Reference Remarks Accel Sensor Out No.1 (Accurate) • Indicates the Accel Sensor Out No.1 (Accurate). • Display range: 0 to 5.000 V IG-ON: 0.75 to 0.95 V (Accel pedal: Close) - Accel Sensor Out No.2 (Accurate) • Indicates the Accel Sensor Out No.2 (Accurate). • Display range: 0 to 5.000 V IG-ON: 1.35 to 1.55 V (Accel pedal: Close) - Pre Glow • Indicates the Pre Glow. • Display range: ON/OFF - Pre Glow demand: ON After Glow • Indicates the After Glow. • Display range: ON/OFF - After Glow demand: ON Target Idle Engine Speed • Indicates the Tar- get Idle Engine Speed. • Display range: 0 to 10000 r/min • It displays a target value of the engine individual • Check "Isochronous Control Target Speed" because it is not sometimes match with engine speed, while still installed on the vehicle. Fuel Return Temp • Indicates the Fuel Return Temp. • Display range: -40 to 215 °C (-40 to 419 °F) - • It displays a value calculated by the engine con- trol computer. EGR Motor Duty #1 • Indicates the EGR Motor Duty #1 • Display range: 0 to 127.5 % 0 to 100% • It displays a value calculated by the engine con- trol computer. 2. Active test (1) With 'Engine Diagnostic Program', according to the instruction of the screen, display the [Active test] screen to perform the active test. SST: 09240-36770-71 Item name Description Constraint condition Control the Select Cylinder Fuel Cut Stop fuel injection of each cylinder #1/ #2/#3/#4 (Injection of multiple cylinders cannot be stopped.) With the machine stopped, during engine rotating Check the Cylinder Compression Stop fuel injection of all cylinders. Measure engine speed during cranking. With the machine stopped, when the crank position sensor and sensor No.2 are in the normal state Control the EGR Step Position Increase or decrease EGR opening degree. When the test is started, opening degree shall be 0. It can be increased or decreased in the range of 0 to 100% by 1%. With the machine stopped, Ignition key switch ON (Engine stop) Activate the EGR Valve Close Forced closed of the EGR valve With the machine stopped, during engine rotating after warm-up
  • 53. 1-52 FAIL SAFE LIST 1. Fail safe list (1) When the codes listed below are recorded in the engine control computer, the machine enters the fail safe mode. Diagnosis code Fail safe operation Condition for canceling the fail safe mode P0046 Limit the engine output. Ignition switch OFF. P0047 Limit the engine output. Ignition switch OFF. P0048 Limit the engine output. Ignition switch OFF. P007C Intake temperature (after turbo charging) is fixed to 170 °C (338 °F). Restore the normal condition. P007D Intake temperature (after turbo charging) is fixed to 170 °C (338 °F). Restore the normal condition. P0087 Limit the engine output. Ignition switch OFF. P0088 Limit the engine output. Ignition switch OFF. P0093 Limit the engine output. Ignition switch OFF. P0102 Limit the engine output. Ignition switch OFF. P0103 Limit the engine output. Ignition switch OFF. P0107 Intake manifold pressure is fixed to 101.3 kPa. Restore the normal condition. P0108 Intake manifold pressure is fixed to 101.3 kPa. Restore the normal condition. P0112 Intake temperature is fixed to 60 °C (140 °F). Restore the normal condition. P0113 Intake temperature is fixed to 60 °C (140 °F). Restore the normal condition. P0115 Temperature is fixed to 119 °C (246 °F) when the fuel temperature sensor is abnormal. When fuel temperature is 15 °C (59 °F) or less: Substitute a value of the fuel temperature sensor. When fuel temperature is 15 °C (59 °F) or more: It is fixed to 119 °C (246 °F). Restore the normal condition. P0117 Temperature is fixed to 119 °C (246 °F) when the fuel temperature sensor is abnormal. When fuel temperature is 15 °C (59 °F) or less: Substitute a value of the fuel temperature sensor. When fuel temperature is 15 °C (59 °F) or more: It is fixed to 119 °C (246 °F). Restore the normal condition. P0118 Temperature is fixed to 119 °C (246 °F) when the fuel temperature sensor is abnormal. When fuel temperature is 15 °C (59 °F) or less: Substitute a value of the fuel temperature sensor. Restore the normal condition. P0180 Fuel temperature is fixed to 50 °C (122 °F). Restore the normal condition. P0182 Fuel temperature is fixed to 50 °C (122 °F). Restore the normal condition. P0183 Fuel temperature is fixed to 50 °C (122 °F). Restore the normal condition. P0190 Limit the engine output. Ignition switch OFF. P0192 Limit the engine output. Ignition switch OFF. P0193 Limit the engine output. Ignition switch OFF. P0201 Limit the engine output. Turn the ignition switch OFF and then ON. Alternatively, turn STA ON. P0202 Limit the engine output. Turn the ignition switch OFF and then ON. Alternatively, turn STA ON. P0203 Limit the engine output. Turn the ignition switch OFF and then ON. Alternatively, turn STA ON. 1KD_RM.book 52 ページ 2013年9月27日 金曜日 午後12時47分
  • 54. 1-53 P0204 Limit the engine output. Turn the ignition switch OFF and then ON. Alternatively, turn STA ON. P0299 Limit the engine output. Restore the normal condition. P0335 Limit the engine output. Restore the normal condition. P0339 Limit the engine output. Restore the normal condition. P0340 Limit the engine output. Restore the normal condition. P0405 Limit the engine output. Ignition switch OFF. P0406 Limit the engine output. Ignition switch OFF. P042E Limit the engine output. Ignition switch OFF. P0489 Limit the engine output. Ignition switch OFF. P0490 Limit the engine output. Ignition switch OFF. P0606 Limit the engine output. Restore the normal condition. P060A Limit the engine output. Restore the normal condition. P060B Limit the engine output. Restore the normal condition. P0627 Limit the engine output. Restore the normal condition. P062D When only one cylinder is abnormal, engine out- put is limited. When two or more cylinders are abnormal, the engine stalls. Ignition switch OFF. P1229 Limit the engine output. Ignition switch OFF. P1251 Limit the engine output. Ignition switch OFF. P2120 Limit the engine output. Restore the normal condition. P2121 Limit the engine output. Restore the normal condition. P2122 Limit the engine output. Restore the normal condition. P2123 Limit the engine output. Restore the normal condition. P2125 Limit the engine output. Restore the normal condition. P2127 Limit the engine output. Restore the normal condition. P2128 Limit the engine output. Restore the normal condition. P2138 Limit the engine output. Restore the normal condition. P2226 Atmospheric pressure is fixed to 70 kPa. Restore the normal condition. P2228 Atmospheric pressure is fixed to 70 kPa. Restore the normal condition. P2229 Atmospheric pressure is fixed to 70 kPa. Restore the normal condition. P2564 Limit the engine output. Ignition switch OFF. P2565 Limit the engine output. Ignition switch OFF. U0101 Limit the engine output. Restore the normal condition. Diagnosis code Fail safe operation Condition for canceling the fail safe mode 1KD_RM.book 53 ページ 2013年9月27日 金曜日 午後12時47分
  • 55. 1-54 Circuit description The VN turbo charger system consists of the VN turbo charger actuator and the engine control computer. The VN turbo charger has a variable nozzle vane. When the vane is opened and closed, the area of the turbine inlet will be changed. This allows adjustment of pressure and speed of exhaust gas entering the turbine. When the vane is closed, supercharging pressure gets higher. When it is opened, supercharging pressure gets lower. The VN turbo charger actuator consists of the DC motor and the nozzle opening degree sensor. The nozzle opening degree sensor detects opening degree of the variable nozzle vane. The DC motor controls the variable nozzle vane. When the engine control computer opens and closes the variable nozzle vane through the DC motor based on the traveling state, flow speed of exhaust gas is changed, allowing the control of supercharging pressure. When detecting a disconnection or short-circuit in the DC motor circuit, the engine control computer stores a diagnosis code and turns on the engine check indicator. When the variable nozzle vane is stuck close, engine torque when the throttle is opened will be significantly limited. When the variable nozzle vane is stuck open, a response becomes slow and torque decreases when the throttle is opened. However, power reduction during high rotation is smaller than that in the stuck close. P0046 P0047 DTC P0046 Turbocharger Boost Control Circuit Range / Performance DTC P0047 Turbocharger Boost Control Solenoid Circuit Low DTC P0048 Turbocharger Boost Control Solenoid Circuit High DTC check pattern DTC detection conditions 1. Diagnosis conditions 2. Abnormal status 3. Abnormal period 4. Others Inspection position In [Active the VN Turbo Open] of the activsxe test, keep the open (fully opened) and OFF (fully closed) states for five seconds or more. 1. Ignition key switch ON 2. A current of the DC motor is 2.2 A or more. 3. 5 sec. or longer 4. 1 trip • Disconnection, short-circuit, and poor connection of the nozzle opening degree sensor (turbo charger S/A). • DC motor (Turbo charger S/A) • Wire harness or connector • Stuck and slow movement of the nozzle vane (turbo charger S/A) • Engine control computer DTC check pattern DTC detection conditions 1. Diagnosis conditions 2. Abnormal status 3. Abnormal period 4. Others Inspection position In [Active the VN Turbo Open] of the active test, keep the open (fully opened) and OFF (fully closed) states for five seconds or more. 1. Ignition key switch ON 2. A duty ratio of the DC motor is 80% or more, and a current value is 0.5 A or less. 3. Three seconds or more 4. 1 trip • DC motor (Turbo charger S/A) • Wire harness or connector • Engine control computer 1KD_RM.book 54 ページ 2013年9月27日 金曜日 午後12時47分
  • 56. 1-55 P0048 Note: • The following symptoms may occur when the nozzle vane is stuck close and then DTC P0046, P0047, and P0048 are stored. - Hunting where a recovery operation from power reduction is repeated every a few seconds during high- load traveling. • The following symptoms may occur when the nozzle vane is stuck open and then DTC P0046, P0047, and P0048 are stored. - Insufficient output - Rising of the engine torque when the accelerator is depressed becomes slow. Circuit diagram Inspection procedure Caution: When replacing the engine control computer or injector ASSY, initialize and write the corresponding ID code according to the Operation Support Procedure List. (See page 1-16 for the procedure.) Note: Use 'Engine Diagnostic Program' to read the freeze frame data. A part of engine operation condition when the defect occurred is recorded in the freeze frame data. This information is useful for troubleshooting. SST 09111-36760-71(09991-70201) 1. Turn the ignition key switch ON. According to the instruction of the 'Engine Diagnostic Program' screen, read the diagnosis code. (See page 1-13 for the procedure.) Result DTC check pattern DTC detection conditions 1. Diagnosis conditions 2. Abnormal status 3. Abnormal period 4. Others Inspection position In [Active the VN Turbo Open] of the active test, keep the open (fully opened) and OFF (fully closed) states for five seconds or more. 1. Ignition key switch ON 2. DC motor overcurrent 3. 25 times or more (about 0.4 second or more) 4. 1 trip • DC motor (Turbo charger S/A) • Wire harness or connector • Engine control computer A U DC motor (Turbo charger S/A) Engine control Computer Shield cable 2 1 42 43 VNM+ VNM- 1 Diagnosis code reading Result Go to P0046, P0047, or P0048 is output. A P0046, P0047, P0048, and other diagnosis codes are output. B 1KD_RM.book 55 ページ 2013年9月27日 金曜日 午後12時47分
  • 57. 1-56 A 1. Turn ON the ignition switch. 2. Press [Active test] and select [Test the Turbo Charger Motor] on the 'Engine Diagnostic Program'. 3. Monitor [VNT Command] and [Actual VN Position] from the data list items. 4. Implement the active test. Result A 1. Disconnect the DC motor (turbo charger S/A) connector. 2. Measure the resistance between terminals. Resistance OK B Go to the related diagnosis code chart (See page 1-5 for the procedure.) 2 Active test implementation (Test the Turbo Charger Motor) Result Go to The value of the [Actual VN Position] follows that of the [VNT Command]. A The value of the [Actual VN Position] does not follow that of the [VNT Command]. B B Go to step 3. INSPECTION OF IRREGULAR PROBLEMS (See page 1-15 for the procedure) 3 Turbo charger S/A inspection (individual inspection) 1 2 DC motor (Turbo charger S/A) M+ M- Inspection terminal Inspection condition Standard 2 (M+) - 1 (M-) Always 1 to100 Ω NG Go to step 6. 4 Wire harness and connector inspection (DC motor (Turbo charger S/A) - Engine control computer) 1KD_RM.book 56 ページ 2013年9月27日 金曜日 午後12時47分
  • 58. 1-57 Note: See page 0-13 for the inspection procedure and notes of wire harness and connectors. 1. Disconnect the connector A of engine control computer and the connector U of DC motor (turbo charger S/A). 2. Measure the resistance between terminals using a tester. (See page 1-33 for the terminal layout.) Resistance Resistance OK 1. Replace the turbo charger S/A. (See page 2-19 for the procedure.) 1. Repair or replace the wire harness or connector. Next SST 09111-36760-71(09991-70201) 1. Turn ON the ignition switch. 2. According to the instruction of the 'Engine Diagnostic Program' screen, delete the diagnosis code. (See page 1-13 for the procedure.) 3. After turning OFF the ignition switch, perform the diagnostic code reading after 30 seconds. Next A U 1 2 Engine control computer Connector on the machine side DC motor (Turbo charger S/A) Connector on the machine side 42(VNM+) 43(VNM-) M+ M- Inspection terminal Inspection condition Standard A-42 (VNM+) - U-2 (M-) Always Less than 1 Ω A-43 (VNM-) - U-1 (M+) Always Less than 1 Ω Inspection terminal Inspection condition Standard A-42 (VNM+) and U-2 (M-) - Other terminal and body ground Always 10 kΩ or more A-43 (VNM-) and U-1 (M+) - Other terminal and body ground Always 10 kΩ or more NG Go to step 6. 5 Turbo charger S/A replacement Next Go to step 7. 6 Wire harness or connector repair or replacement 7 Diagnosis code deletion 1KD_RM.book 57 ページ 2013年9月27日 金曜日 午後12時47分
  • 59. 1-58 SST 09111-36760-71(09991-70201) 1. Turn ON the ignition switch. 2. Press [Active test]  select [Activate the VN Turbo Open] on the 'Engine Diagnostic Program'. 3. Perform the active test and keep the open (fully opened) and OFF (fully closed) states for 5 seconds or more. 4. According to the instruction of the 'Engine Diagnostic Program' screen, check that no diagnosis code is output. (See page 1- 13 for the procedure.) Next 8 Diagnosis code reading End 1KD_RM.book 58 ページ 2013年9月27日 金曜日 午後12時47分
  • 60. 1-59 Circuit description The inlet air temperature sensor is attached to the intake pipe to measure the intake air temperature. The resistance value of thermistor included in the inlet air temperature sensor varies with the change in intake air temperature. The resistance value of thermistor increases as the intake air temperature falls, or decreases as the intake air temperature rises. The inlet air temperature sensor is connected to the engine control computer, and 5 V power supply voltage is supplied to the sensor from the THIA terminal of engine control computer via the resistor R. Since the resistor R and inlet air temperature sensor are connected in series, the resistance value varies with the change in intake air temperature and also the THIA terminal potential changes. According to this signal, the engine control computer increases the fuel injection amount or advance the injection timing when the intake air temperature is low to improve the drivability. P007C DTC P007C Charge Air Cooler Temperature Sensor Circuit Low DTC P007D Charge Air Cooler Temperature Sensor Circuit High DTC check pattern DTC detection conditions 1. Diagnosis conditions 2. Abnormal status 3. Abnormal period 4. Others Inspection position 1 sec. with ignition key switch ON 1. Ignition key switch ON 2. Shorting of inlet air temperature sensor circuit 3. 0.5 sec. or longer 4. 1 trip • Wire harness or connector • Inlet air temperature sensor (for intake manifold) • Engine control computer Resistance [kΩ] Temperature [°C] 30 20 10 5 3 2 1 0.5 0.3 0.2 0.1 -20 0 20 40 60 80 100 1KD_RM.book 59 ページ 2013年9月27日 金曜日 午後12時47分
  • 61. 1-60 P007D Related Data List Circuit diagram Inspection procedure Caution: When replacing the engine control computer or injector ASSY, initialize and write the corresponding ID code according the Operation Support Procedure List. (See page 1-16 for the procedure.) Note: Use 'Engine Diagnostic Program' to read the freeze frame data. A part of engine operation condition when the defect occurred is recorded in the freeze frame data. This information is useful for troubleshooting. DTC check pattern DTC detection conditions 1. Diagnosis conditions 2. Abnormal status 3. Abnormal period 4. Others Inspection position 1 sec. with ignition key switch ON 1. Ignition key switch ON 2. Disconnection of inlet air temper- ature sensor circuit 3. 0.5 sec. or longer 4. 1 trip • Wire harness or connector • Inlet air temperature sensor (for intake manifold) • Engine control computer DTC No. Data list P007C P007D Intake air temperature after turbocharging A P Inlet air temperature sensor (for intake manifold) Engine control computer 2 1 113 90 THIA ETHI 1KD_RM.book 60 ページ 2013年9月27日 金曜日 午後12時47分
  • 62. 1-61 SST 09111-36760-71(09991-70201) 1. Turn the ignition key switch ON and read [Intake Air Temp (Turbo)] displayed on the 'Engine Diagnostic Program' while the engine is stopped. Result Note: *: The result is normal at the moment but should be checked if the defect reappears. (See page 1-15 for Inspection of irregular problems) A SST(1) 09111-36760-71(09991-70201) SST(2) 09160-36760-71(09843-18040) 1. Disconnect the connector P of inlet air temperature sensor. 2. Using 'diagnosis check wire No.2', short circuit the terminals between the terminal 1 and 2 of inlet air temperature sensor connector of the truck side. 3. Turn the ignition key switch ON. 4. Read [Intake Air Temp (Turbo)] displayed on the 'Engine Diagnostic Program'. Standard Display temperature 190 °C (374 °F) NG 1 'Engine Diagnostic Program' data reading (intake air temperature after turbocharging) Result Go to -40 °C (-40 °F) (disconnection) A 190 °C (374 °F) (short circuit) B Same as temperature around intake manifold* C B Go to step 4. C Go to step 9. 2 'Engine Diagnostic Program' data reading (wire harness disconnection check) 1 2 P Inlet air temperature sensor (for intake manifold) Connector on the machine side Inlet air temperature Sensor Engine control Computer OK Go to step 7. 1KD_RM.book 61 ページ 2013年9月27日 金曜日 午後12時47分