SEN06575-02

ENGINE 86E-7 - 98E-7 SERIES

(With common rail injection system)
 TNV Tier 4 Service Manual
TABLE OF
CONTENTS
Structure and Function, Testing and Adjusting, Disassembly and
Assembly, and Maintenance Standard
Page
Introduction ......................................................................................... 1-1
Applicable machine............................................................................. 2-1
Safety.................................................................................................... 3-1
General Service Information .............................................................. 4-1
Periodic Maintenance ......................................................................... 5-1
Engine .................................................................................................. 6-1
Fuel System ......................................................................................... 7-1
Cooling System .................................................................................... 8-1
Lubrication System ............................................................................. 9-1
Turbocharger ..................................................................................... 10-1
Starter Motor...................................................................................... 11-1
Alternator ........................................................................................... 12-1
Electronic Control System ............................................................... 13-1
Electric Wiring ................................................................................... 14-1

Troubleshooting
Failure Code (DTC) General Description......................................... 15-1
Method and Procedure of Failure Diagnosis .................................. 16-1
Mechanical System Failure Diagnosis ............................................ 17-1

86E-7 – 98E-7 Series

TABLE OF CONTENTS

ii 86E-7 – 98E-7 Series

STRUCTURE AND FUNCTION,
TESTING AND ADJUSTING,
DISASSEMBLY AND ASSEMBLY,
AND MAINTENANCE STANDARD

86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 1

INTRODUCTION
How to read the shop manual
• Some of the attachments and options described in this shop manual may not be available in some areas.
If they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop
manual for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown
in the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided
into "Structure and Function, Testing and Adjusting, Disassembly and Assembly, and Maintenance
Standard" and "Troubleshooting" section for the ease of use.
Basic informaton
This Shop Manual describes the service procedures for 86E – 98E-7 series engines have common rail
injection system.
Please use this manual for accurate, quick and safe servicing of the engine. Since the directions in this
manual are for a typical engine, some specifications and components may be different from your engine.
For the replacement of some parts and troubleshooting for this series engines, the Diagnostics Tool called
SMARTASSIST-Direct is required. In addition, please read both “Troubleshooting” Section and
SMARTASSIST-Direct Operation Manual.
Note
• The injectors of this series engines are located from the flywheel side to the cooling fan side as follows;
1st cylnder, 2nd cylinder, ...

86E-7 – 98E-7 Series 1-1

INTRODUCTION
• SMARTASSIST-DIRECT (SA-D) display indicates this series engine as fallows.

Engine model SA-D display

3D88E-7 3TNV88C
S3D86E-7 3TNV86CT
4D88E-7 4TNV88C
S4D86E-7 4TNV86CT
4D98E-7 4TNV98C
S4D98E-7 4TNV98CT

Komatsu products are continuously undergoing improvement. This Shop Manual might not address
possible field modifications to the equipment. Contact an authorized dealer or distributor for answers to any
questions relating to field modifications.

1-2 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 2

APPLICABLE MACHINE
Engine Applicable machine
3D88E-7 - -
S3D86E-7 -
PC45MR-5
4D88E-7 Hydraulic excavator
PC55MR-5
S4D86E-7 - -
4D98E-7 - -
S4D98E-7 - -

86E-7 – 98E-7 Series 2-1

APPLICABLE MACHINE

2-2 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 3

SAFETY
Page
Safety Statements .................................................................................. 3-3
Safety Precautions ............................................................................... 3-10
During Operation and Maintenance ............................................... 3-10

86E-7 – 98E-7 Series 3-1

SAFETY

3-2 86E-7 – 98E-7 Series

Safety Statements SAFETY

SAFETY STATEMENTS
Komatsu is concerned for your safety and your machine’s condition. Safety statements are one of the
primary ways to call your attention to the potential hazards associated with the engine operation. Follow the
precautions listed throughout the manual before operation, during operation and during periodic
maintenance procedures for your safety, the safety of others and to protect the performance of your
engine. Keep the labels from becoming dirty or torn and replace them if they are lost or damaged. Also, if
you need to replace a part that has a label attached to it, make sure you order the new part and label at the
same time.

This safety alert symbol appears with most safety statements. It means attention, become
alert, your safety is involved! Please read and abide by the message that follows the safety
alert symbol.

Precautions for preparatory work

• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or
tracks to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not
possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure
to lock all the control levers and hang "UNDER REPAIR" warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks,
jacks, or stands before starting the work.
• Remove all mud and oil from the steps or other places
for going up and down on the machine. Always use the
handrails, ladders or steps when for going up and down
on the machine. Never jump on or off the machine.
When the scaffold is not provided, use steps or
stepladder to secure your footing. Do not use handrails,
ladders, or steps if they are damaged or deformed.
Repair it or replace it immediately.
,&
Precautions during work
• For the machine equipped with the battery disconnect switch, check that the system operating lamp is off
before starting the work. Then, turn the battery disconnect switch to OFF (○) position and remove the
switch key.
For the machine not equipped with the battery disconnect switch, turn the starting switch to OFF position,
and wait for at least two minutes before starting the work. Then, disconnect the battery cable.

86E-7 – 98E-7 Series 3-3

SAFETY Safety Statements

Precautions for slinging work and making signals

• Only one appointed worker must make signals and co-workers must communicate with each other
frequently.
The appointed signaler must make specified signals clearly at a place where he is well seen from the
operator's seat and where he can see the working condition easily. The signaler must always stand in
front of the load and guide the operator safely.
k Never stand under the load.
k Do not move a load over a person.
k Do not step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load
even if the crane starts abruptly.
• Check the slings before starting sling work.
• Keep putting on gloves during sling work. (Put on leather gloves, if available.)
• Measure the weight of the load by the eye and check its center of gravity.
• Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes
are used to sling a light load, the load may slip and fall.
• Do not sling a load with 1 wire rope alone. If it is slung so, It may rotate and may slip out of the rope.
Install 2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a
dangerous accident.
• Hanging angle must be 60 ° or smaller as a rule.
• When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of
the hook.
a When slinging a load with 2 or more ropes, the force
subjected to each rope increases with the hanging angle.
The figure below shows the variation of allowable load in
kN {kg} when slinging is made with 2 ropes, each of
which is allowed to sling up to 9.8 kN {1000 kg} vertically,
at various hanging angles. When the 2 ropes sling a load
vertically, they can sling up to 2000 kg of total weight.
This weight is reduced to 1000 kg when the 2 ropes
make a hanging angle of 120 °. If the 2 ropes sling a
2000 kg load at a hanging angle of 150 °, each rope is
subjected to a force as large as 39.2 kN {4000 kg}.

3-4 86E-7 – 98E-7 Series

Safety Statements SAFETY
• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch
system.
k Slinging near the tip of the hook may cause the
rope to slip off the hook during hoisting.
a The strength of the hook is maximum at its central
part.

• Never use a wire rope which has breaks in strands (A),

reduced diameter (B), or kinks (C). There is a danger
that the rope may break during the towing operation.
Precautions for slinging up
• Wind in the crane slowly until wire ropes are stretched.
When settling the wire ropes with the hand, do not grasp
them but press them from above. If you grasp them, your
fingers may be caught.
• After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes,
and pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load at an angle.
Precautions for slinging down
• When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the
specified place.

Precautions for using mobile crane

a Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.

86E-7 – 98E-7 Series 3-5

SAFETY Safety Statements

Precautions for using overhead traveling crane

kWhen raising a heavy component (heavier than 25 kg), use a hoist or crane.
• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device,
ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and
energizing caution lamp, and check the following safety items.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Be sure to check the directions of the direction indication plate (north, south, east and west) and the
operating button.
• Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
• Do not raise or lower a load while the crane is moving longitudinally or laterally.
• Do not drag a sling.
• When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
• Consider the travel route in advance and lift up a load to a safe height.
• Place the control switch in a position where it is not an obstacle to work and passage.
• After operating the hoist, do not swing the control switch.
• Remember the position of the main switch so that you can turn off the power immediately in an
emergency.
• If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it
is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not
in operating condition.
• If you find an obstacle around the hoist, stop the operation.
• After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above
the floor. Do not leave the sling installed to the hook.

3-6 86E-7 – 98E-7 Series

Safety Statements SAFETY
Selecting wire ropes
Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.
a The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.
Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing)

Nominal diameter of rope (mm) Allowable load (kN {t})

10 8.8 {0.9}
12 12.7 {1.3}
14 17.3 {1.7}
16 22.6 {2.3}
18 28.6 {2.9}
20 35.3 {3.6}
25 55.3{5.6}
30 79.6 {8.1}
40 141.6 {14.4}
50 221.6 {22.6}
60 318.3 {32.4}

Precautions for disposing of waste materials

Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with
the local regulations for disposing industrial waste products.

86E-7 – 98E-7 Series 3-7

SAFETY Safety Statements

Drying wiring harness

a If
the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam
washing. If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring
harness. If water gets directly on the connector, do as follows.
1. Disconnect the connector and wipe off the water with a
dry cloth.
a If the connector is to be blown with dry compressed
air, there is the risk that oil in the air may cause
defective contact, remove oil and water in the air
before starting air blow.

2. Dry the inside of the connector with a dryer.

If water enters inside the connector, use a dryer to dry
the connector.
a Hot air from a dryer can be used, but limit the time of
using a dryer to prevent the connector or related parts
from becoming too hot, as this will cause deformation
or damage to the connector.

3. Perform a continuity test on the connector.

After drying, leave the wiring harness disconnected,
connect T-adapter (1) and perform a continuity test to
check for any short circuits between pins caused by
water or etc.
a After the connector is completely dried, blow the
contact restorer, and reassemble them.

3-8 86E-7 – 98E-7 Series

Safety Statements SAFETY
Handling controller
kWhen performing arc welding on the machine body,
disconnect all of the wiring harness connectors
connected to the controller. Fit an arc welding
ground close to the welding point.
a Controller has been assembled with electronic circuits
for control including microcomputers. These electronic
circuits inside of the controller must be handled with care
since they control the machine.
a Do not leave things on the controller.

a Cover the connector portion of the controller with a tape

and a plastic bag. Do not touch the connecting portion of
connector.
a Do not leave the controller in a place where it is exposed
to rain.
a Do not place the controller on oil, water, soil or any
places where the temperature is likely to be high even
for a short period of time (Place it on a suitable dry
stand).

86E-7 – 98E-7 Series 3-9

SAFETY Safety Precautions

SAFETY PRECAUTIONS
During Operation and Maintenance
DANGER
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.

WARNING
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.

CAUTION
CAUTION indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.

NOTICE
NOTICE indicates a situation which can cause
damage to the machine, personal property and/or
the environment or cause the equipment to operate
improperly.

3-10 86E-7 – 98E-7 Series

Safety Precautions SAFETY

DANGER DANGER
High Pressure Hazard! Explosion Hazard!
• This engine uses a high-pressure • Keep the area around the battery
common rail system. For well-ventilated. While the engine
disassembly of the high pressure is running or the battery is
parts (e.g. the high-pressure pipe) charging, hydrogen gas is
in particular, be sure to wait produced which can be easily
approximately 10 to 15 minutes ignited.
before performing disassembly. • Keep sparks, open flame and any other form
• Do not loosen the high pressure pipe while of ignition away while the engine is running or
the engine is running, even in low idle. This is battery is charging.
dangerous because fuel under high pressure • Never check the remaining battery charge by
will blow out. shorting out the terminals. This will result in a
• Failure to comply will result in death or spark and may cause an explosion or fire. Use
serious injury. a hydrometer to check the remaining battery
charge.
Scald Hazard! • If the electrolyte is frozen, slowly warm the
battery before you recharge it.
• Never remove the radiator cap if
the engine is hot. Steam and hot • Failure to comply will result in death or
engine coolant will spurt out and serious injury.
seriously burn you. Allow the
engine to cool down before you
Crush Hazard!
attempt to remove the radiator
cap. • When you need to transport an
engine for repair, have a helper
• Tighten the radiator cap securely after you assist you to attach it to a hoist
check the radiator. Steam can spurt out and load it on a truck.
during engine operation if the cap is loose.
• Always check the level of the engine coolant • Never stand under a hoisted engine. If the
by observing the reserve tank. hoist mechanism fails, the engine will fall on
• Failure to comply will result in death or you, causing death or serious injury.
serious injury. • Failure to comply will result in death or
serious injury.

86E-7 – 98E-7 Series 3-11

SAFETY Safety Precautions

DANGER DANGER (Continued)

Fire and Explosion Hazard! • Be sure to place the diesel fuel container on
• Diesel fuel is flammable and the ground when transferring the diesel fuel
explosive under certain from the pump to the container. Hold the hose
conditions. nozzle firmly against the side of the container
while filling it. This prevents static electricity
buildup which could cause sparks and ignite
fuel vapors.
• When you remove any fuel system
component to perform maintenance (such as • Never place diesel fuel or other flammable
changing the fuel filter) place an approved material such as oil, hay or dried grass close
container under the opening to catch the fuel. to the engine during engine operation or
shortly after shutdown.
• Never use a shop rag to catch the fuel. Vapors
from the rag are flammable and explosive. • Before you operate the engine, check for fuel
leaks. Replace rubberized fuel hoses every
• Wipe up any spills immediately. two years or every 4000 hours of engine
• Wear eye protection. The fuel system is under operation, whichever comes first, even if the
pressure and fuel could spray out when you engine has been out of service. Rubberized
remove any fuel system component. fuel lines tend to dry out and become brittle
after two years or 4000 hours of engine
• Only use the key switch to start the engine.
operation, whichever comes first.
• Never jump-start the engine. Sparks caused
• Never remove the fuel cap with the engine
by shorting the battery to the starter terminals
running.
may cause a fire or explosion.
• Never use diesel fuel as a cleaning agent.
• If the unit has an electric fuel pump, when you
prime the fuel system, turn the key switch to • Place an approved container under the air
the ON position for 10 to 15 seconds to allow bleed port when you prime the fuel system.
the electric fuel pump to prime the system. Never use a shop rag to catch the fuel. Wipe
up any spills immediately. Always close the
• If the unit has a mechanical fuel pump, when
air bleed port after you complete priming the
you prime the fuel system, operate the fuel
system.
priming lever of the mechanical fuel pump
several times until the fuel filter cup is filled • Wear eye protection. The fuel system is under
with fuel. pressure and fuel could spray out when you
open the air bleed port.
• Only fill the fuel tank with diesel fuel. Filling
the fuel tank with gasoline may result in a fire • If the unit has an electric fuel pump, turn the
and will damage the engine. key switch to the ON position for 10 to 15
seconds, or until the fuel coming out of the air
• Never refuel with the engine running.
bleed port is free of bubbles, to allow the
• Keep sparks, open flames or any other form electric fuel pump to prime the system.
of ignition (match, cigarette, static electric
• If the unit has a mechanical fuel pump,
source) well away when refueling.
operate the fuel priming pump several times
• Never overfill the fuel tank. until the fuel coming out of the air bleed port
• Fill the fuel tank. Store any containers is free of bubbles.
containing fuel in a well-ventilated area, away • Failure to comply will result in death or
from any combustibles or sources of ignition. serious injury.

3-12 86E-7 – 98E-7 Series

Safety Precautions SAFETY

WARNING WARNING
Sever Hazard! Exhaust Hazard!
• Keep hands and other body parts • Never operate the engine in an
away from moving/rotating parts enclosed area such as a garage,
such as the cooling fan, flywheel tunnel, underground room,
or PTO shaft. manhole or ship’s hold without
proper ventilation.
• Wear tight-fitting clothing and keep your hair • Never block windows, vents, or other means
short or tie it back while the engine is of ventilation if the engine is operating in an
running. enclosed area. All internal combustion
• Remove all jewelry before you operate or engines create carbon monoxide gas during
service the machine. operation. Accumulation of this gas within an
enclosure could cause illness or even death.
• Never start the engine in gear. Sudden
movement of the engine and/or machine • Make sure that all connections are tightened
could cause death or serious personal injury. to specifications after repair is made to the
exhaust system.
• Never operate the engine without the guards
in place. • Failure to comply could result in death or
serious injury.
• Before you start the engine make sure that all
bystanders are clear of the area.
Alcohol and Drug Hazard!
• Keep children and pets away while the engine
is operating. • Never operate the engine while
you are under the influence of
• Check before starting the engine that any alcohol or drugs.
tools or shop rags used during maintenance
have been removed from the area.
• Failure to comply could result in death or • Never operate the engine when you are
serious injury. feeling ill.
• Failure to comply could result in death or
serious injury.

86E-7 – 98E-7 Series 3-13

SAFETY Safety Precautions

WARNING WARNING
Exposure Hazard! Burn Hazard!
• Wear personal protective • Batteries contain sulfuric acid.
equipment such as gloves, work Never allow battery fluid to come
shoes, eye and hearing protection in contact with clothing, skin or
as required by the task at hand. eyes. Severe burns could result.
Always wear safety goggles and
• Never wear jewelry, unbuttoned cuffs, ties or protective clothing when
loose-fitting clothing when you are working servicing the battery. If battery
near moving/rotating parts such as the fluid contacts the eyes and/or
cooling fan, flywheel or PTO shaft. skin, immediately flush the
affected area with a large amount
• Always tie back long hair when you are of clean water and obtain prompt
working near moving/rotating parts such as a medical treatment.
cooling fan, flywheel, or PTO shaft.
• Failure to comply could result in death or
• Never operate the engine while wearing a serious injury.
headset to listen to music or radio because it
will be difficult to hear the alert signals.
High-Pressure Hazard!
• Failure to comply could result in death or
serious injury. • Avoid skin contact with the
high-pressure diesel fuel spray
caused by a fuel system leak
Burn Hazard! such as a broken fuel injection
• If you must drain the engine oil line. High-pressure fuel can
while it is still hot, stay clear of penetrate your skin and result in
the hot engine oil to avoid being serious injury. If you are exposed
burned. to high-pressure fuel spray,
obtain prompt medical treatment.
• Always wear eye protection. • Never check for a fuel leak with your hands.
Always use a piece of wood or cardboard.
• Wait until the engine cools before you drain
Have your authorized dealer or distributor
the engine coolant. Hot engine coolant may
repair the damage.
splash and burn you.
• Failure to comply could result in death or
• Keep your hands and other body parts away
serious injury.
from hot engine surfaces such as the muffler,
exhaust pipe, turbocharger (if equipped) and
engine block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the engine is
operating and could seriously burn you.
• Failure to comply could result in death or
serious injury.

3-14 86E-7 – 98E-7 Series

Safety Precautions SAFETY

WARNING WARNING
Shock Hazard! To prevent possible eye injury,
• Turn off the battery switch (if always wear safety glasses while
equipped) or disconnect the servicing the engine.
negative battery cable before
servicing the electrical system.

• Check the electrical harnesses for cracks, Fume/Burn Hazard!

abrasions, and damaged or corroded • Always read and
connectors. Always keep the connectors and follow safety related
terminals clean. precautions found on
• Failure to comply could result in death or containers of
serious injury. hazardous substances
like parts cleaners,
primers, sealants and
Entanglement Hazard! sealant removers.
• Stop the engine before you begin
• Failure to comply could result in death or
to service it.
serious injury.

Never apply over 40 psi (2.8 kgf/cm2) to the

• Never leave the key in the key switch when waste gate actuator.
you are servicing the engine. Someone may
accidentally start the engine and not realize
you are servicing it. This could result in a • Never inject fuel toward you. Since the fuel is
serious injury. injected at high pressure from the nozzle, it
may penetrate the skin, resulting in injury.
• If you must service the engine while it is
operating, remove all jewelry, tie back long • Never inject fuel toward a fire source.
hair, and keep your hands, other body parts Atomized fuel is highly flammable and may
and clothing away from moving/rotating parts. cause a fire or burn skin.

• Failure to comply could result in death or

serious injury. • Never use the ECU for other purposes than
intended or in other ways than specified by
Komatsu. Doing so could result in the
Sudden Movement Hazard! violation of emission control regulations and
• Engaging the transmission or PTO at an will void the product warranty.
elevated engine speed could result in
• Improper use or misuse of the ECU may result
unexpected movement of the equipment.
in death or serious injury due to an abrupt
• Failure to comply could result in death or and unexpected increase in engine speed.
serious injury.

86E-7 – 98E-7 Series 3-15

SAFETY Safety Precautions

WARNING CAUTION
• Be sure to use the ECU in conjunction with Coolant Hazard!
the engines whose models or serial numbers • Wear eye protection
are specified by Komatsu. and rubber gloves
Other ECU/engine combinations than when you handle non-
specified will void the engine warranty. amine engine coolant
• Improper use or misuse of the ECU may result (AF-NAC). If contact
in death or serious injury due to an abrupt with the eyes or skin
and unexpected increase in engine speed. should occur, flush
eyes and wash
immediately with
• Replacing the fuel injector involves rewriting clean water.
the injector trim data in the ECU.
Be sure to contact your authorized dealer • Failure to comply may result in minor or
before replacing the fuel injector. moderate injury.
Failure to rewrite the injector trim data before
replacing the fuel injector will void the engine Flying Object Hazard!
warranty.
• Always wear eye protection when
• Improper use or misuse of the ECU may result servicing the engine and when
in death or serious injury due to an abrupt using compressed air or high-
and unexpected increase in engine speed. pressure water. Dust, flying
debris, compressed air,
pressurized water or steam may
• Replacing the ECU involves migrating the fuel injure your eyes.
injection data to the existing ECU to the new
unit. • Failure to comply may result in minor or
Be sure to contact your authorized dealer moderate injury.
before replacing the ECU.
Failure to migrate the fuel injection data Be sure to secure the engine solidly to prevent
before replacing the ECU will void the engine injury or damage to parts due to the engine
warranty. falling during work on the engine.
• Improper use or misuse of the ECU may result
in death or serious injury due to an abrupt
and unexpected increase in engine speed. Pinch Hazard!
Carefully rotate the alternator
toward the cylinder block while
loosening the V-belt. Failure to
comply may result in minor or
moderate injury.

If any oil pump component clearance exceeds

its limit, the oil pump must be replaced as an
assembly.

3-16 86E-7 – 98E-7 Series

Safety Precautions SAFETY

NOTICE NOTICE
• Only use diesel fuels recommended by Komatsu Observe the following environmental operating
for the best engine performance, to prevent conditions to maintain engine performance and
engine damage and to comply with EPA/ARB avoid premature engine wear:
warranty requirements.
• Avoid operating in extremely dusty conditions.
• Only use clean diesel fuel.
• Avoid operating in the presence of chemical
• Never remove the primary strainer (if equipped) gases or fumes.
from the fuel tank filler port. If removed, dirt and
debris could get into the fuel system causing it to • Avoid operating in a corrosive atmosphere such
clog. as salt water spray.
• Never install the engine in a floodplain unless
proper precautions are taken to avoid being
Never attempt to adjust the low or high idle speed subject to a flood.
limit screw. This may impair the safety and
performance of the machine and shorten its life. If • Never expose the engine to the rain.
adjustment is ever required, contact your
authorized dealer or distributor.
Observe the following environmental operating
conditions to maintain engine performance and
If any problem is noted during the visual check, the avoid premature engine wear:
necessary corrective action should be taken before
you operate the engine. • The standard range of ambient temperatures for
the normal operation of this series engines is
from +5 °F (-15 °C) to +113 °F (+45 °C).
Never hold the key in the START position for longer • If the ambient temperature exceeds +113 °F (+45
than 15 seconds or the starter motor will overheat. °C) the engine may overheat and cause the
engine oil to break down.
If the engine start fails, wait 30 seconds before you • If the ambient temperature is below +5 °F (-15
start the engine again. °C) the engine will be hard to start and the engine
oil may not flow easily.

Make sure the engine is installed on a level • Contact your authorized dealer or distributor if the
surface. If a continuously running engine is engine will be operated outside of this standard
installed at an angle greater than (30°) in any temperature range.
direction or if an engine runs for short periods of
time (less than three minutes) at an angle greater
than (35°) in any direction, engine oil may enter the The illustrations and descriptions of optional
combustion chamber causing excessive engine equipment in this manual, such as the operator’s
speed and white exhaust smoke. This may cause console, are for a typical engine installation. Refer
serious engine damage. to the documentation supplied by the optional
equipment manufacturer for specific operation and
maintenance instructions.

86E-7 – 98E-7 Series 3-17

SAFETY Safety Precautions

NOTICE NOTICE
If any indicator illuminates during engine operation, For maximum engine life, Komatsu recommends
stop the engine immediately. Determine the cause that when shutting the engine down, you allow the
and repair the problem before you continue to engine to idle, without load, for five minutes. This
operate the engine. will allow the engine components that operate at
high temperatures, such as the turbocharger (if
equipped) and exhaust system, to cool slightly
• Only use the engine oil specified by Komatsu. before the engine itself is shut down.
Other engine oils may affect warranty coverage,
cause internal engine components to seize
and/or shorten engine life. Never use an engine starting aid such as ether.
Engine damage will result.
• Prevent dirt and debris from contaminating the
engine oil. Carefully clean the oil cap/dipstick and
the surrounding area before you remove the cap. • Always be environmentally
• Never mix different types of engine oil. This may responsible.
adversely affect the lubricating properties of the
engine oil.
• Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal • Follow the guidelines of the EPA or other
damage. governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
• Only use the engine coolant specified by authorities or reclamation facility.
Komatsu. Other engine coolants may affect • Never dispose of hazardous materials
warranty coverage, cause an internal buildup of irresponsibly by dumping them into a sewer, on
rust and scale and/or shorten engine life. the ground, or into ground water or waterways.
• Prevent dirt and debris from contaminating the • Failure to follow these procedures may seriously
engine coolant. Carefully clean the radiator cap harm the environment.
and the surrounding area before you remove the
cap.
• Never mix different types of engine coolants. This Never engage the starter motor while the engine is
may adversely affect the properties of the engine running. This may damage the starter motor pinion
coolant. and/or ring gear.

• Never overfill the engine with engine oil.

• Always keep the oil level between the upper and
lower lines on the oil cap/dipstick.

3-18 86E-7 – 98E-7 Series

Safety Precautions SAFETY

NOTICE NOTICE
New engine break-in: The tightening torque in the Standard Torque Chart
(see General Service Information section) should
• On the initial engine start-up, allow the engine to be applied only to the bolts with a “7” head. (JIS
idle for approximately 15 minutes while you check strength classification: 7T)
for proper engine oil pressure, diesel fuel leaks,
engine oil leaks, coolant leaks, and for proper • Apply 60 % torque to bolts that are
operation of the indicators and/or gauges. not listed.
• During the first hour of operation, vary the engine • Apply 80 % torque when tightened to
speed and the load on the engine. Short periods aluminum alloy.
of maximum engine speed and load are
desirable. Avoid prolonged operation at minimum
or maximum engine speeds and loads for the If any indicator fails to illuminate when the key
next four to five hours. switch is in the ON position, see your authorized
dealer or distributor for service before operating the
• During the break-in period, carefully observe the engine.
engine oil pressure and engine temperature.
• During the break-in period, check the engine oil
Establish a periodic maintenance plan according to
and coolant levels frequently.
the engine application and make sure you perform
the required periodic maintenance at the intervals
• Never attempt to modify the engine’s design or indicated. Failure to follow these guidelines will
safety features such as defeating the engine impair the engine’s safety and performance
speed limit control or the fuel injection quantity characteristics, shorten the engine’s life and may
control. affect the warranty coverage on your engine.

• Failure to comply may impair the engine’s safety Consult your authorized dealer or distributor for
and performance characteristics and shorten the assistance when checking items marked with a ●.
engine’s life. Any alterations to this engine may
affect the warranty coverage of your engine.
If the fuel filter/water separator is positioned higher
than the fuel level in the fuel tank, water may not
Protect the air cleaner, turbocharger (if equipped) drip out when the fuel filter/water separator drain
and electric components from damage when you cock is opened. If this happens, turn the air vent
use steam or high-pressure water to clean the screw on the top of the fuel filter/water separator 2 -
engine. 3 turns counterclockwise.
Be sure to tighten the air vent screw after the water
has drained out.
Never use high-pressure water or compressed air
at greater than 28 psi (193 kPa; 19686 mmAq) or a
wire brush to clean the radiator fins. Radiator fins
damage easily.

86E-7 – 98E-7 Series 3-19

SAFETY Safety Precautions

NOTICE NOTICE
• When the engine is operated in dusty conditions, Do not turn the battery switch OFF while the engine
clean the air cleaner element more frequently. is operating. Damage to the alternator will result.
• Never operate the engine with the air cleaner
element(s) removed. This may allow foreign Do not operate the engine if the alternator is
material to enter the engine and damage it. producing unusual sounds. Damage to the
alternator will result.
The maximum air intake restriction, in terms of
differential pressure measurement, must not If the engine coolant pump must be replaced,
exceed 0.90 psi (6.23 kPa; 635 mmAq). Clean or replace the engine coolant pump as an assembly
replace the air cleaner element if the air intake only. Do not attempt to repair the engine coolant
restriction exceeds the above mentioned value. pump or replace individual components.

It is important to perform daily checks. Use a new special O-ring between the engine
Periodic maintenance prevents unexpected coolant pump and the joint. Be sure to use the
downtime, reduces the number of accidents due to special O-ring for each engine model. Although the
poor machine performance and helps extend the O-ring dimensions are the same as a commercially
life of the engine. available O-ring, the material is different.

If the oil pump must be replaced, replace it as an Remove or install the high-pressure fuel injection
assembly only. Do not replace individual lines as an assembly whenever possible.
components. Disassembling the high-pressure fuel injection lines
from the retainers or bending any of the fuel lines
will make it difficult to reinstall the fuel lines.
The starter motor can be damaged if operated
continuously longer than 10 seconds while
performing the no-load test. After marking the position of the pump drive gear,
do not rotate the engine crankshaft. Rotating the
crankshaft will cause the fuel supply pump to
Do not short-circuit the charging system between become misaligned.
alternator terminals IG and L. Damage to the
alternator will result.
Do not use a high-pressure wash directly on the
alternator. Water will damage the alternator and
Do not connect a load between alternator terminals result in inadequate charging.
L and E. Damage to the alternator will result.
Do not reverse the positive (+) and negative (-)
Do not remove the positive (+) battery cable from ends of the battery cable. The alternator diode and
alternator terminal B while the engine is operating. stator coil will be damaged.
Damage to the alternator will result.

3-20 86E-7 – 98E-7 Series

Safety Precautions SAFETY

NOTICE NOTICE
When the battery indicator goes out, it should not Make sure that the combined total resistance of the
come on again. The battery indicator only comes battery cable in both directions between the starter
on during operation if the alternator fails. However, motor and the battery is within the value indicated
if an LED is used in the battery indicator, the LED in the Battery Cable Resistance chart in the Electric
will shine faintly during normal operation. Wiring Section of this manual. The starter motor will
malfunction and fail if the resistance is higher than
the specified value.
Using a non-specified V-belt will cause inadequate
charging and shorten the belt life. Use the specified
belt. Removing the battery cables or the battery while
the engine is operating may cause damage to the
current limiter depending on the electrical
Agricultural or other chemicals, especially those with equipment being used. This situation could cause
a high sulfur content, can adhere to the IC regulator. loss of control of output voltage. The continuous
This will corrode the conductor and result in battery high voltage of 23 - 24 volts (for 5000 min-1 (rpm)
over-charging (boiling) and charging malfunctions. dynamo) will damage the current limiter and other
Consult Komatsu before using the machine in such electrical equipment.
an environment or the warranty is voided.

Reversing the battery cable connections at the

Make sure that the combined total resistance of the battery or on the engine will destroy the SCR diode
battery cable in both directions between the starter in the current limiter. This will cause the charging
motor and the battery is within the value indicated system to malfunction and may cause damage to
on the wiring diagram. The starter motor will the electrical harnesses.
malfunction or break down if the resistance is
higher than the specified value.
Avoid damage to the turbocharger or the engine.
Do not spray blower wash fluid or water too quickly.
The starter motor is water-proofed according to JIS
D 0203, R2 which protects the motor from rain or Use short strokes from a spray bottle to inject
general cleaning. Do not use high-pressure wash blower wash fluid or water into the turbocharger.
or submerse the starter motor in water.
Spraying too much wash fluid or water, or spraying
too quickly will damage the turbocharger.
Use a specialized battery charger to recharge a
battery with a voltage of 8 volts or less. Booster
Do not allow any material to fall into the oil lines or
starting a battery with a voltage of 8 volts or less will
the oil inlet and outlet ports of the turbocharger.
generate an abnormally high voltage and destroy
electrical equipment.
If the waste valve does not meet specifications,
replace the turbocharger or have it repaired by a
When unavoidably using a rapid charger to recharge,
qualified repair facility.
do not insert and turn the starter key to ON position
while the battery is being charged. Avoid using a
charger equipped with a boost function (cell start
support) to start the engine. The ECU may be
damaged by applied excessive voltage.

86E-7 – 98E-7 Series 3-21

SAFETY Safety Precautions

NOTICE NOTICE
• Never attempt to modify the engine’s design or Any part determined to not meet the service
safety features such as defeating the engine standard or limit before the next service, as
speed limit control or the diesel fuel injection determined from the state of current rate of wear,
quantity control. should be replaced even though the part currently
meets the service standard limit.
• Modifications may impair the engine’s safety and
performance characteristics and shorten the
engine’s life. Any alterations to this engine may Never use a steel wire brush to clean fuel injectors.
void its warranty. Be sure to use Komatsu Damage to the nozzle and other components is
genuine replacement parts. likely to result.

Identify all parts and their location using an Allow the engine to warm-up for at least five
appropriate method. It is important that all parts are minutes and the idle speed of the engine to return
returned to the same position during the to normal before engaging the transmission or any
reassembly process. PTOs. Engaging the transmission or PTO at an
elevated engine speed could result in an
unexpected movement of the machine.
Each pressure adjusting shim removed or added
changes the pressure threshold by approximately
275 psi (1.9 MPa, 19 kgf/cm2). Adding adjusting Shut down the engine if the fault indicator comes
shims increases the threshold pressure. Removing on.
adjusting shims reduces the pressure threshold.
Continuing running the engine with the fault
indicator being on may result in a serious
Keep the piston pin parts, piston assemblies, and malfunction of or damage to the engine, and will
connecting rod assemblies together to be returned void the engine warranty.
to the same position during the reassembly
process. Label the parts using an appropriate
method. Do not energize the starter for a period of longer
than 15 seconds.

Do not allow the honing tool to operate in one Take a pause of at least 30 seconds between
position for any length of time. Damage to the energization of the starter.
cylinder wall will occur. Keep the tool in constant Otherwise the starter could suffer damage.
up-and-down motion.

• High-pressure washing not recommended.

Any part which is found defective as a result of
inspection or any part whose measured value does • Avoid using high-pressure washing for electronic
not satisfy the standard or limit must be replaced. or electric devices installed in, on or around the
engine, including the E-ECU, relays and harness
couplers.
Otherwise such devices may suffer malfunction due
to water ingress into them.

3-22 86E-7 – 98E-7 Series

Safety Precautions SAFETY

NOTICE NOTICE
Always check the battery for proper charge. • Never permit anyone to operate the
engine or driven machine without
Otherwise the electronically controlled engines may proper training.
fail to start.

• Do not plug or unplug the ECU for a period of at • Read and understand this Shop Manual before
least 6 seconds after power to the unit has been you operate or service the machine to ensure that
turned on or off. you follow safe operating practices and
maintenance procedures.
• Do not touch connector pins of the ECU with bare
hands. Doing so may result in corrosion of the • Machine safety signs and labels are additional
connector pins and/or damage to the internal reminders for safe operating and maintenance
circuits of the ECU due to static electricity. techniques.
• Do not force a measuring probe into the female • See your authorized dealer or distributor for
coupler. Doing so may cause contact failure of additional training.
the connector pins, resulting in malfunction of the
ECU.
• Take care to prevent water from entering the
couplers when plugging or unplugging the
connector. Water inside the couplers may cause
corrosion, resulting in malfunction of the ECU.
• Avoid plugging/unplugging the connector more
than approx. 10 times.
Frequent plugging/unplugging of the connector
may cause contact failure of the connector pins,
resulting in malfunction of the ECU.
• Do not use the ECU that has ever suffered drop
impact.

86E-7 – 98E-7 Series 3-23

SAFETY Safety Precautions

3-24 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 4

GENERAL SERVICE
INFORMATION
Page
Component Identification........................................................................ 4-3
Function of Major Engine Components .................................................. 4-5
Function of Cooling System Components .............................................. 4-6
Main Electronic Control Components and Features............................... 4-7
Installation Position of Sensors .............................................................. 4-9
Crank Rotation Sensor ................................................................... 4-10
Cam Speed Sensor ........................................................................ 4-10
New Air Temperature Sensor......................................................... 4-11
EGR Temperature Sensor.............................................................. 4-11
Intake Temperature Sensor............................................................ 4-11
Fuel Temperature Sensor (equipped on supply pump).................. 4-12
Cooling Water Temperature Sensor............................................... 4-12
Diesel Particulate Filter (KDPF) Inside/Inlet,
Exhaust Temperature Sensor ........................................................ 4-13
Rail Pressure Sensor ..................................................................... 4-13
EGR Pressure Sensor.................................................................... 4-14
Diesel Particulate Filter (KDPF) Differential Pressure Sensor ....... 4-15
EGR Valve...................................................................................... 4-16
Intake Air Throttles ......................................................................... 4-17
Acceleration Sensor (Example)...................................................... 4-18
Diesel Fuel ........................................................................................... 4-19
Diesel Fuel Specifications .............................................................. 4-19
Filling The Fuel Tank...................................................................... 4-20
Priming the Fuel System ................................................................ 4-21
Engine Oil............................................................................................. 4-22
Engine Oil Specifications................................................................ 4-22
Engine Oil Viscosity........................................................................ 4-22

86E-7 – 98E-7 Series 4-1

GENERAL SERVICE INFORMATION
Checking Engine Oil........................................................................4-23
Adding Engine Oil ...........................................................................4-23
Engine Oil Capacity (Typical)..........................................................4-23
Engine Coolant......................................................................................4-24
Filling Radiator with Engine Coolant ...............................................4-25
Daily Check of the Cooling System.................................................4-26
Engine Coolant Capacity (Typical)..................................................4-26
Specifications ........................................................................................4-27
Description of Model Number..........................................................4-27
Engine General Specifications ........................................................4-27
Principal Engine Specifications .............................................................4-29
3D88E-7 ..........................................................................................4-29
S3D86E-7........................................................................................4-30
4D88E-7 ..........................................................................................4-31
S4D86E-7........................................................................................4-32
4D98E-7 ..........................................................................................4-33
S4D98E-7........................................................................................4-34
Set Output Listed by Rotation .........................................................4-35
Engine Service Standards.....................................................................4-36
Tightening Torques for Standard Bolts and Nuts ..................................4-37
Abbreviations and Symbols...................................................................4-38
Unit Conversions...................................................................................4-39

4-2 86E-7 – 98E-7 Series

Component Identification GENERAL SERVICE INFORMATION

COMPONENT IDENTIFICATION
■ 3D88E-7, S3D86E-7, 4D88E-7, S4D86E-7
Figure 4-1 shows where the major engine components are located.

1 2 3 4 5 19 20 21 22 23

18 17 16 15 14 13 12 11 10 9 8 7 6 27 26 25 24 043922-00X01

1 – Fuel inlet 15 – Dipstick (engine oil)

2 – Fuel return to fuel tank 16 – Intake manifold
3 – Turbocharger*1 17 – Common rail
4 – Air intake port (from air cleaner) 18 – Intake throttle valve
5 – Engine coolant pump 19 – Top filler port (engine oil)
6 – Engine cooling fan 20 – Lifting eye (engine cooling fan end)
7 – Crankshaft V-pulley 21 – Rocker arm cover
8 – V-belt 22 – Lifting eye (flywheel end)
9 – Fuel filter 23 – Diesel Particulate Filter (KDPF)
10 – Side filler port (engine oil) 24 – Flywheel
11 – Drain plug (engine oil)*2 25 – Starter motor
12 – Supply pump 26 – Exhaust manifold
13 – Engine oil cooler 27 – Alternator
14 – Engine oil filter
Figure 4-1

*1: Only applies to S3D86E-7 and S4D86E-7.

*2: The engine oil drain plug location may vary based on oil pan options.

86E-7 – 98E-7 Series 4-3

GENERAL SERVICE INFORMATION Component Identification

■ 4D98E-7, S4D98E-7
Figure 4-2 shows where the major engine components are located.

1 2 3 4 17 18 19

16 15 14 13 12 11 10 9 8 7 6 5 25 24 23 22 21 20044738-01X00

1 – Lifting eye (flywheel end) 14 – Drain plug (cooling water)

2 – Lifting eye (engine cooling fan end) 15 – Common rail
3 – Diesel Particulate Filter (KDPF) 16 – Intake throttle valve
4 – Engine coolant pump 17 – Top filler port (engine oil)
5 – Engine cooling fan 18 – Turbocharger*1
6 – Crankshaft V-pulley 19 – Rocker arm cover
7 – V-belt 20 – Flywheel
8 – Fuel filter 21 – Drain plug (engine oil)*2
9 – Side filler port (engine oil) 22 – Starter motor
10 – Supply pump 23 – Exhaust manifold
11 – Engine oil cooler 24 – EGR cooler
12 – Engine oil filter 25 – Alternator
13 – Dipstick (engine oil)
Figure 4-2

*1: Only applies to S4D98E-7.

*2: Engine oil drain plug location may vary based on oil pan options.

4-4 86E-7 – 98E-7 Series

Function of Major Engine Components GENERAL SERVICE INFORMATION

FUNCTION OF MAJOR ENGINE COMPONENTS

Components Functions
Air cleaner The air cleaner prevents airborne contaminants from entering the engine.
Periodic replacement of the air cleaner filter element is necessary.
Alternator The alternator is driven by a V-belt which is powered by the crankshaft V-
pulley. The alternator supplies electricity to the engine systems and charges
the battery while the engine is running.
Dipstick (engine oil) The engine oil dipstick is used to determine the amount of engine oil in the
crankcase.
Electric fuel pump The electric fuel pump makes sure there is a constant supply of diesel fuel
to the fuel injection pump. The electric fuel pump is electro-magnetic and
runs on 12 V DC. It must be installed on every application. This is standard
equipment with every engine.
Engine oil filter The engine oil filter removes contaminants and sediments from the engine
oil. Periodic replacement of the engine oil filter is necessary.
Engine oil cooler The engine oil cooler helps to keep the engine oil cool. Engine coolant from
the cooling system is circulated through an adapter at the base of the engine
oil filter assembly and then returned to the coolant pump inlet.
Fuel filter The fuel filter removes contaminants and sediments from the diesel fuel.
Periodic replacement of the fuel filter is necessary.
Please note that the word “diesel” is implied throughout this manual
when the word “fuel” is used.
Water separator The water separator removes contaminants, sediment and water from
diesel fuel going to the fuel filter. This is a required component of the fuel
system and is standard equipment with every engine. The water separator
is installed between the fuel tank and the fuel feed pump. Periodically drain
the water from the water separator using the drain cock at the bottom of the
separator and replace the filter element.
Fuel tank The fuel tank is a reservoir that holds diesel fuel. When the fuel leaves the
fuel tank it goes to the fuel filter/water separator. Next the fuel is pumped to
the fuel filter by the electric fuel pump. Then the fuel goes to the fuel injection
pump. Since the fuel is used to keep the fuel injection pump cool and
lubricated, more fuel than necessary enters the injection pump. When the
injection pump pressure reaches a preset value, a relief valve allows the
excess fuel to be returned back to the fuel tank. The fuel tank is a required
engine component.
Fuel cooler The fuel cooler prevents the fuel temperature from rising. The fuel cooler is
equipped between the fuel filter and the supply pump.
Side and top filler port (engine oil) You can fill the crankcase with engine oil from either the side or the top
filler port depending upon which one is most convenient.
Starter motor The starter motor is powered by the battery. When you turn the key switch
in the operator’s console to the START position, the starter motor engages
with the ring gear installed on the flywheel and starts the flywheel in motion.
Turbocharger (only applies to The turbocharger pressurizes the air coming into the engine. It is driven by
S3D86E-7, S4D86E-7, S4D98E-7) a turbine that is energized by exhaust gases.

86E-7 – 98E-7 Series 4-5

GENERAL SERVICE INFORMATION Function of Cooling System Components

FUNCTION OF COOLING SYSTEM COMPONENTS

Components Functions
Cooling system This series engine is liquid-cooled by means of a cooling system. The
cooling system consists of a radiator, radiator cap, engine cooling fan,
engine coolant pump, thermostat, and reserve tank.
• Engine cooling fan The engine cooling fan is driven by a V-belt which is powered by the
crankshaft V-pulley. The purpose of the engine cooling fan is to circulate air
through the radiator.
• Engine coolant pump The engine coolant pump circulates the engine coolant through the cylinder
block and the cylinder head and returns the engine coolant to the radiator.
• Radiator The radiator acts as a heat exchanger. As the engine coolant circulates
through the cylinder block it absorbs heat. The heat in the engine coolant is
dissipated in the radiator. As the engine cooling fan circulates air through
the radiator, the heat is transferred to the air.
• Radiator cap The radiator cap controls the cooling system pressure. The cooling system
is pressurized to raise the boiling point of the engine coolant. As the engine
coolant temperature rises, the system pressure and the coolant volume
increases. When the pressure reaches a preset value, the release valve in
the radiator cap opens and the excess engine coolant flows into the reserve
tank. As the engine coolant temperature is reduced, the system pressure
and volume is reduced and the vacuum valve in the radiator cap opens
allowing the engine coolant to flow from the reserve tank back into the
radiator.
• Reserve tank The reserve tank contains the overflow of engine coolant from the radiator.
If you need to add engine coolant to the system, add it to the reserve tank;
not the radiator.
• Thermostat A thermostat is placed in the cooling system to prevent the engine coolant
from circulating into the radiator until the engine coolant temperature
reaches a preset temperature. When the engine is cold, no engine coolant
flows through the radiator. Once the engine reaches its operating
temperature, the thermostat opens and allows the engine coolant to flow
through the radiator. By letting the engine warm up as quickly as possible,
the thermostat reduces engine wear, deposits and emissions.

4-6 86E-7 – 98E-7 Series

 GENERAL SERVICE INFORMATION
Main Electronic Control Components and Features

MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES

Component/feature Description
Controller By controlling the fuel injection timing, injection volume,
injection pressure, and number of injection in accordance with
the target speed indication entered from the accelerator sensor,
the controller adjusts the engine speed and power.
Depending on the above-mentioned speed and power, the
controller controls the EGR opening. Also, the controller acts as
the key station of the application function.
Fuel pump (supply pump) The fuel pump supplies fuel to the common rail.
Common rail The common rail stores the compressed high-pressure fuel
from the supply pump and distributes fuel to the injector in each
cylinder.
Fuel injector The Fuel Injectors inject the high-pressure fuel from the rail to
the engine combustion room after receiving a signal from the
ECU in the most appropriate injection timing, injection volume,
injection ratio, number of injection and spray condition.
EGR valve Controls the exhaust gas recirculation flow rate depending on
the engine speed/load signals from the ECU. It is installed on
the top of the exhaust manifold.
Diesel Particulate Filter (KDPF) The Diesel Particulate Filter (KDPF) consists of the diesel
oxidation catalyst (KDOC) and the soot filter (SF). It is a device
to prevent the discharge of particulate matter (PM) by breaking
down the hazardous constituent with the KDOC and collecting
the PM in the exhaust gas with the SF.
Intake throttle valve The intake throttle adjusts the amount of intake air in the engine
and controls the exhaust temperature to assist the KDPF
regeneration.
Accelerator sensor Unlike mechanical governors, the Eco-governor has no
governor lever. The accelerator sensor serves as the governor
lever to provide the speed command signal (voltage signal) to
the ECU for engine speed control. It is installed in the operator
cabin of the driven machine. Constant speed engines for e.g.
generator use do not require accelerator sensors because the
engine speed can be shifted via a switch on the operator's
console.
Optional CAN communication capability is available as an option.
Fault indicator Is installed on the operator’s console. If a fault occurs in the
ECU or Eco-governor, the fault indicator flashes alerting the
operator to a fault. The number of flashes and/or the flashing
pattern vary depending on the type or source of the fault,
Optional enabling quick-fix.

86E-7 – 98E-7 Series 4-7

GENERAL SERVICE INFORMATION
Main Electronic Control Components and Features

Component/feature Description
SMARTASSIST-DIRECT This tool can also be used for data maintenance tasks including
programming and mapping. Allows the operator to troubleshoot
the cause of a problem based on detailed information regarding
the problem occurring in the ECU.

Option for service

Engine coolant temperature sensor Allows the fuel injection volume and EGR to be controlled in
engine cold-start conditions.
Glow plugs Optional When the key switch is turned to the ON position, the glow
plugs/air heater are/is energized for up to 15 seconds (glow
plugs). The duration of energization depends on the engine
coolant temperature. The HEAT indicator is on during
energization. When the indicator goes out, turn the key switch
to the START position to start the engine.
Droop control Standard with VM series Reduces the engine speed by a certain percentage from no
load to full (rated) load in steady state operation. The same
percentage droop is maintained even when the load increases
at any no-load speed.
Isochronous control Standard with CL series Offers a constant engine speed from no load to full load. The
Optional with VM series engine speed does not decrease even when the load increases
at any no-load speed.
Low-idling speed up When the engine is cold, increases the low-idling speed to up to
1000 min-1 (rpm) depending on the engine coolant temperature.
When the coolant temperature reaches a predetermined value,
this feature returns the engine speed to the normal low idle
setting, thus reducing the warm-up time.
High-idling speed Turbocharged The high-idling speed is controlled to 1500 min-1 when starting
down specification the engine in cold weather conditions (-15 °C or below).
At least 10 seconds after the engine starts, the engine speed
returns to the normal high idle setting by operating the
accelerator lever, thus preventing the seizures of the
turbocharger.
Auto deceleration Optional Brings the running engine in low idle mode automatically when
the accelerator pedal is not operated for a predetermined period
of time. When the pedal is operated, i.e., the accelerator sensor
is activated, the low idle mode is cancelled.

4-8 86E-7 – 98E-7 Series

Installation Position of Sensors GENERAL SERVICE INFORMATION

INSTALLATION POSITION OF SENSORS

Do not unnecessarily touch the sensor coupler portion with your bare hands.
The sensor may be damaged due to static electricity.

Injector
KDPF inlet exhaust temperature
sensor Exhaust temperature sensor
KDPF inside exhaust temperature
sensor EGR valve
KDPF differential pressure sensor EGR pressure sensor

Cooling water temperature

sensor

Intake air throttles

Crank rotation sensor

Cam speed sensor
New air temperature sensor
EGR temperature sensor Pump discharge control
valve
Intake temperature sensor
Fuel temperature sensor
Rail pressure sensor 044896-00EN01

Figure 4-3

86E-7 – 98E-7 Series 4-9

GENERAL SERVICE INFORMATION Installation Position of Sensors

Crank Rotation Sensor

037282-00X00

Figure 4-4

Part No. YM129A00-21710

Sensor installation tightening torque 8 ± 2 N·m

Cam Speed Sensor

037283-00X00

Figure 4-5

Part No. YM129A00-14710

Sensor installation tightening torque 8 ± 0.5 N·m

4-10 86E-7 – 98E-7 Series

 Installation Position of Sensors GENERAL SERVICE INFORMATION
New Air Temperature Sensor

037253-00X00

Figure 4-6

Part No. YM129A00-12711

Sensor installation With turbocharger 7.0 ± 1.4 N·m
tightening torque Without turbocharger 3.5 ± 0.5 N·m

EGR Temperature Sensor

044575-00X00

Figure 4-7

Part No. YM129A00-13751

Sensor installation tightening torque 14 ± 3 N·m

Intake Temperature Sensor

044574-00X00

Figure 4-8

Part No. YM129A00-12720

Sensor installation tightening torque 14 ± 3 N·m

86E-7 – 98E-7 Series 4-11

GENERAL SERVICE INFORMATION Installation Position of Sensors

Fuel Temperature Sensor (equipped on supply pump)

MPROP

Fuel temperature sensor

037312-00E00

Figure 4-9

Part No. YM129A00-51200

Sensor installation tightening torque 28 ± 2 N·m

Cooling Water Temperature Sensor

037249-00X00

Figure 4-10

Part No. YM129927-44900

Sensor installation tightening torque 22 ± 2 N·m

4-12 86E-7 – 98E-7 Series

Installation Position of Sensors GENERAL SERVICE INFORMATION
Diesel Particulate Filter (KDPF) Inside/Inlet, Exhaust Temperature Sensor

037254-00X00

Figure 4-11

Exhaust temperature KDPF inside exhaust KDPF inlet exhaust

sensor temperature sensor temperature sensor
Part No. YM129A00-13760 (Main) YM129C00-13950 (Main) YM129C00-13940 (Main)
Sensor installation
32.5 ± 7.5 N·m 40 ± 5 N·m 40 ± 5 N·m
tightening torque
Safety precaution Do not lift the KDPF by holding the sensor part.

Note: The parts numbers for the sensors are different depending on the engine model.
Refer to the Parts Book for the correct parts number when replacing.

Rail Pressure Sensor

037318-00X00

Figure 4-12

Part No. YM129A00-57100

Sensor installation tightening torque 95 ± 5 N·m

86E-7 – 98E-7 Series 4-13

GENERAL SERVICE INFORMATION Installation Position of Sensors

EGR Pressure Sensor

PS-X429
**** **

Vin Vout (Intake side)

GND Vout (Exhaust side)

BLANK BLANK

Intake side 40° 40° 40°

ALLOWABLE 40° ALLOWABLE
MOUNTING ANGULAR MOUNTING ANGULAR
Exhaust side
037257-00E00

Figure 4-13

Part No. YM129A00-12703

Sensor installation tightening torque 7 ± 1.4 N·m

4-14 86E-7 – 98E-7 Series

Installation Position of Sensors GENERAL SERVICE INFORMATION
Diesel Particulate Filter (KDPF) Differential Pressure Sensor

PS-X434
**** ** Vin Vout (High pressure side)

GND Vout (Differential pressure side)

BLANK Vout (Low pressure side)

40° 40° ALLOWABLE

High pressure side MOUNTING ANGULAR
40° ALLOWABLE
40° MOUNTING ANGULAR
Low pressure side
037255-00E00

Figure 4-14

Part No. YM129A00-17702

Sensor installation tightening torque 7 ± 1.4 N·m
If you install a pipe to the KDPF differential pressure
sensor, do not install it as shown in the below figure. If
water collects, the pressure cannot be detected.

Good Bad
Diff. press. sensor Diff. press. sensor
Safety precaution
Pipe

Water collects
037256-00E00

Differential pressure sensor pipe installation (example)

86E-7 – 98E-7 Series 4-15

GENERAL SERVICE INFORMATION Installation Position of Sensors

EGR Valve

037280-00X00

Figure 4-15

3D88E-7, S3D86E-7 4D88E-7, S4D86E-7 4D98E-7, S4D98E-7

Part No. YM129A00-13901 YM129C00-13901 YM129E00-13901

4-16 86E-7 – 98E-7 Series

Installation Position of Sensors GENERAL SERVICE INFORMATION
Intake Air Throttles

Motor terminal
Sensor terminal

037319-00E00

Figure 4-16

Part No. YM129A00-12900

Sensor installation tightening torque 9.0 ± 1.8 N·m
Be sure to read the precautions before handling the
Safety precaution
intake throttle.

86E-7 – 98E-7 Series 4-17

GENERAL SERVICE INFORMATION Installation Position of Sensors

Acceleration Sensor (Example)

77

72
High idle (3.0 V)
57°
Low idle (0.5 V) 73° Working range position (3.65 V - 4.35 V)

70

A
Mating connector:
B 6189-0780
(Sumitomo Wiring Systems Ltd.)
terminal: gold plate
C 032910-00E

Figure 4-17

Terminal Wire
A GND GND-A
B OUTPUT APS
C INPUT AVCC

Rated voltage DC 5 V ± 0.01 V

Part No. YM129938-77800
Total resistance (sensor unit) 5 ± 1.5 k

4-18 86E-7 – 98E-7 Series

Diesel Fuel GENERAL SERVICE INFORMATION

DIESEL FUEL
Diesel Fuel Specifications • Metal content of Mg, Si, and Al should be equal to
or lower than 1 mass ppm. (Test analysis method
Diesel fuel should comply with the following JPI-5S-44-95)
specifications. The table lists several worldwide
specifications for diesel fuels. • The diesel fuel should be free from Zn and Na.
Diesel fuel specification Location • Lubricity: Wear mark of WS1.4 should be Max.
ASTM D975 USA 0.018 in. (460 µm) at HFRR test.
No. 1D S15
No. 2D S15 ■ Precautions and concerns regarding the
EN590:96 European Union use of diesel fuel
ISO 8217 DMX International • Never use kerosene.
BS 2869-A1 or A2 United Kingdom • Never mix kerosene or used engine oil with the
JIS K2204 Grade No. 2 Japan diesel fuel.
KSM-2610 Korea
GB252 China
• Never use residual fuels that cause diesel fuel
filter clogging and carbon deposits on the
nozzles.
■ Additional technical fuel requirements
• Never use fuels stored for long time in a drum can
• When operating the engine in cold districts or or the like.
high altitudes, the fuel cetane number should be
equal to 45 or higher. • Never use fuels purchased from unauthorized
dealer.
• The sulfur content must not exceed 15 ppm
by volume. A higher sulfur content fuel may • Fuel additives are not recommended. Some fuel
cause sulfuric acid corrosion in the cylinders additives may cause poor engine performance.
of the engines. Especially in U.S.A. and Consult your Komatsu representative for more
Canada, Ultra Low Sulfur fuel must be used. information.
• Use the fuel that can be used where the
■ Bio-diesel fuels
temperature is 12 °C (53.6 °F) lower than the
expected lowest temperature to prevent the fuel In Europe and in the United States, as well as some
from freezing. other countries, non-mineral oil based fuel
resources such as RME (Rapeseed Methyl Ester)
• Bio-diesel fuels. See Bio-diesel fuels on and SOME (Soybean Methyl Ester), collectively
page 4-19. known as FAME (Fatty Acid Methyl Esters), are
• Water and sediment in the fuel should not exceed being used as extenders for mineral oil derived
0.05 % by volume. diesel fuels.

• Ash content not to exceed 0.01 % by volume. Komatsu approves the use of bio-diesel fuels that
• Carbon residue content not to exceed 0.35 % by do not exceed a blend of 7 % (by volume) of FAME
volume. Less than 0.1 % is preferred. with 93 % (by volume) of approved mineral oil
derived diesel fuel. Such bio-diesel fuels are known
• Total aromatics content should not exceed 35 % in the marketplace as B7 diesel fuels.
by volume. Less than 30 % is preferred.
• PAH (Polycyclic Aromatic Hydrocarbons) content
should be below 10 % by volume.

86E-7 – 98E-7 Series 4-19

GENERAL SERVICE INFORMATION Diesel Fuel

These B7 diesel fuels must meet certain Filling The Fuel Tank
requirements.
• The bio-fuels must meet the minimum specifications DANGER
for the country in which they are used.
Fire and Explosion Hazard!
• In Europe, bio-diesel fuels must comply with • Diesel fuel is flammable and
the European Standard for both EN14214 and explosive under certain
EN590 (for Oxidation stability). conditions.
• In the United States, bio-diesel fuels must
comply with the American Standard for both
ASTM D-6751 and ASTM D-7467 (for • Only fill the fuel tank with diesel fuel. Filling
Oxidation stability). the fuel tank with gasoline may result in a fire
• Bio-fuels should be purchased only from and will damage the engine.
recognized and authorized diesel fuel suppliers. • Never refuel with the engine running.
Precautions and concerns regarding the use of • Wipe up all spills immediately.
bio-fuels:
• Keep sparks, open flames or any other form
• Free methanol in FAME may result in corrosion of of ignition (match, cigarette, static electric
aluminum and zinc FIE components. source) well away when refueling.
• Free water in FAME may result in plugging of fuel • Never overfill the fuel tank.
filters and increased bacterial growth.
• Fill the fuel tank. Store any containers
• High viscosity at low temperatures may result in containing fuel in a well-ventilated area, away
fuel delivery problems, supply pump seizures, from any combustibles or sources of ignition.
and poor injection nozzle spray atomization.
• Be sure to place the diesel fuel container on
• FAME may have adverse effects on some the ground when transferring the diesel fuel
elastomers (seal materials) and may result in fuel from the pump to the container. Hold the hose
leakage and dilution of the engine lubricating oil. nozzle firmly against the side of the container
while filling it. This prevents static electricity
• Even bio-diesel fuels that comply with a suitable
buildup which could cause sparks and ignite
standard as delivered, will require additional care
fuel vapors.
and attention to maintain the quality of the fuel in
the equipment or other fuel tanks. It is important • Never place diesel fuel or other flammable
to maintain a supply of clean, fresh fuel. Regular material such as oil, hay or dried grass close
flushing of the fuel system, and/or fuel storage to the engine during engine operation or
containers, may be necessary. shortly after shutdown.
• Use bio diesel fuel within 2 months after filling it to • Before you operate the engine, check for fuel
the fuel tank, or within 3 months after its leaks. Replace rubberized fuel hoses every
production at the manufacturer. two years or every 4000 hours of engine
The use of bio-diesel fuels that do not comply operation, whichever comes first, even if the
with the standards as agreed to by the diesel engine has been out of service. Rubberized
engine manufacturers and the diesel fuel injection fuel lines tend to dry out and become brittle
equipment manufacturers, or biodiesel fuels that after two years or 4000 hours of engine
have degraded as per the precautions and operation, whichever comes first.
concerns above, may affect the warranty
coverage of your engine. • Failure to comply will result in death or
serious injury.

4-20 86E-7 – 98E-7 Series

Diesel Fuel GENERAL SERVICE INFORMATION

NOTICE NOTICE
• Only use diesel fuels recommended by Komatsu Check the fuel level gauge in the fuel tank daily and
for the best engine performance, to prevent ensure that the engine does not run out of fuel.
engine damage and to comply with EPA/ARB Seizure to the supply pump may occur.
warranty requirements.
• Only use clean diesel fuel.
Priming the Fuel System
• Poor quality fuel can reduce engine performance
and/or cause engine damage. DANGER
• Keep the fuel tank and fuel-handling equipment Fire and Explosion Hazard!
clean at all times.
• Diesel fuel is flammable and
• Never remove the primary strainer (if equipped) explosive under certain
from the fuel tank filler port. If removed, dirt and conditions.
debris could get into the fuel system causing it to
clog.
• If the unit has an electric fuel pump, when you
prime the fuel system, turn the key switch to
Note that a typical fuel tank is shown. The fuel tank the ON position for 10 to 15 seconds to allow
on your equipment may be different. the electric fuel pump to prime the system.
1. Clean the area around the fuel cap • Failure to comply will result in death or
(Figure 4-18, (1)). serious injury.
2. Remove the fuel cap from the fuel tank
(Figure 4-18, (2)).
The fuel system needs to be primed under certain
3. Observe the fuel level sight gauge conditions:
(Figure 4-18, (3)) and stop filling when gauge
shows fuel tank is full. Never overfill the fuel • Before starting the engine for the first time.
tank. • After running out of fuel and fuel has been added
4. Replace the fuel cap (Figure 4-18, (1)), hand to the fuel tank.
tighten. Over tightening the fuel cap will
damage it. • After fuel system maintenance such as changing
the fuel filter and draining the fuel filter/water
separator, or replacing a fuel system component.
1
To prime the fuel system:
1. Turn the key to the ON position for 10 to 15
2 seconds. This will allow the electric fuel pump
to prime the fuel system.
2. Never use the starter motor to crank the engine
in order to prime the fuel system. This may
3 cause the starter motor to overheat and
damage the coils, pinion and/or ring gear.
K0000002A

Figure 4-18

86E-7 – 98E-7 Series 4-21

GENERAL SERVICE INFORMATION Engine Oil

ENGINE OIL
NOTICE NOTICE
• Only use the engine oil specified by Komatsu. • Be sure the engine oil, engine oil storage
Other engine oils may affect warranty coverage, containers, and engine oil filling equipment are
cause internal engine components to seize free of sediments and water.
and/or shorten engine life.
• Change the engine oil at every 500 hours.
• Prevent dirt and debris from contaminating the
engine oil. Carefully clean the oil cap/dipstick and • Select the oil viscosity based on the ambient
the surrounding area before you remove the cap. temperature where the engine is being operated.
See the Operation & Maintenance Manual.
• Never mix different types of engine oil. This may
adversely affect the lubricating properties of the • Komatsu does not recommend the use of engine
engine oil. oil “additives.”

• Never overfill. Overfilling may result in white • Never mix different brands of lubricating oils.
exhaust smoke, engine overspeed or internal • Never use synthetic oil.
damage.

■ Additional technical engine oil

Engine Oil Specifications requirements:
Use an engine oil that meets or exceeds the The engine oil must be changed when the Total
following guidelines and classifications: Base Number (TBN) has been reduced to 1.0
mgKOH/g. TBN (mgKOH/g) test method; JIS K-
■ Service categories 201-5.2-2 (HCI), ASTM D4739 (HCI).
• API service categories CJ-4
Engine Oil Viscosity
• ACEA service categories E6
Select the appropriate engine oil viscosity based on
• JASO service category DH-2 the ambient temperature. See Operation &
Maintenance Manual.
■ Definitions
• API classification (American Petroleum Institute)
• ACEA classification (Association des
Constructeurs Européens d’Automobilies)
• JASO (Japanese Automobile Standards
Organization)

4-22 86E-7 – 98E-7 Series

Engine Oil GENERAL SERVICE INFORMATION
Checking Engine Oil 1 4 5
1. Make sure engine is level.
2. Remove dipstick (Figure 4-19, (1)) and wipe
with clean cloth.
3. Fully reinsert dipstick.
4. Remove dipstick. The oil level should be
between upper (Figure 4-19, (2)) and lower
(Figure 4-19, (3)) lines on the dipstick.
5. Fully reinsert dipstick.

Adding Engine Oil 2 4

1. Make sure engine is level.

2. Remove oil cap (Figure 4-19, (4)).
3. Add indicated amount of engine oil at the top or 3
side engine oil filler port (Figure 4-19, (5)).
4. Wait three minutes and check oil level.
5. Add more oil if necessary.
6. Reinstall oil cap (Figure 4-19, (4)) and
hand-tighten. Over-tightening may damage the 043924-00X00

cap. Figure 4-19

Engine Oil Capacity (Typical)

These are the engine oil capacities associated with
a “Deep Standard” oil pan. Oil capacity will vary
dependent upon which optional oil pan is used.
Refer to the operation manual for the actual engine
oil capacity of your machine.
The following are the engine oil capacities for
various engines.

Dipstick
Engine model
upper limit/lower limit
3D88E-7, S3D86E-7 7.1/4.1 qt (6.7/3.9 l)
4D88E-7, S4D86E-7 7.8/4.2 qt (7.4/4.0 l)
4D98E-7, S4D98E-7 11.1/6.3 qt (10.5/6.0 l)

86E-7 – 98E-7 Series 4-23

GENERAL SERVICE INFORMATION Engine Coolant

ENGINE COOLANT
DANGER CAUTION
Scald Hazard! Coolant Hazard!
• Never remove the radiator cap if • Wear eye protection
the engine is hot. Steam and hot and rubber gloves
engine coolant will spurt out and when you handle non-
seriously burn you. Allow the amine engine coolant
engine to cool down before you (AF-NAC). If contact
attempt to remove the radiator with the eyes or skin
cap. should occur, flush
• Tighten the radiator cap securely after you eyes and wash
check the radiator. Steam can spurt out immediately with
during engine operation if the cap is loose. clean water.

• Always check the level of the engine coolant • Failure to comply may result in minor or
by observing the reserve tank. moderate injury.

• Failure to comply will result in death or NOTICE

serious injury.
• Only use the engine coolant specified by
WARNING Komatsu. Other engine coolants may affect
warranty coverage, cause an internal buildup of
Burn Hazard! rust and scale and/or shorten engine life.
• If you drain the engine oil while it
• Prevent dirt and debris from contaminating the
is still hot, stay clear of the hot
engine coolant. Carefully clean the radiator cap
engine oil to avoid being burned.
and the surrounding area before you remove the
Always wear eye protection when
cap.
you handle the engine coolant.
• Failure to comply could result in death or • Never mix different types of engine coolants. This
serious injury. may adversely affect the properties of the engine
coolant.

4-24 86E-7 – 98E-7 Series

Engine Coolant GENERAL SERVICE INFORMATION
Filling Radiator with Engine Coolant 2. Remove the radiator cap (Figure 4-20, (2)) by
turning it counterclockwise about 1/3 of a turn.
Fill the radiator and reserve tank as follows. This
procedure is for filling the radiator for the first time 3. Pour the engine coolant slowly into the radiator
or refilling it after it is flushed. Note that a typical until it is even with the lip of the engine coolant
radiator is illustrated. filler port. Make sure that air bubbles do not
develop as you fill the radiator.
1. Check to be sure the radiator drain plug is 4. Reinstall the radiator cap (Figure 4-20, (2)).
installed and tightened or the drain cock Align the tabs on the back side of the radiator
(Figure 4-20, (1)) is closed. Also make sure the cap with the notches on the engine coolant filler
coolant hoses (Figure 4-21, (1)) are installed at port. Press down and turn the cap clockwise
the oil cooler. about 1/3 of a turn.
5. Remove the cap of the reserve tank
2 (Figure 4-20, (3)), and fill it to the LOW (COLD)
mark (Figure 4-20, (4)) with engine coolant.
5
Reinstall the cap.
6. Check the hose (Figure 4-20, (5)) that
3 connects the reserve tank (Figure 4-20, (3)) to
the radiator. Be sure it is securely connected
6 FULL

LOW and there are no cracks or damage. If the hose

4 is damaged, engine coolant will leak out instead
of going into the reserve tank.
7. Run the engine until it reaches operating
temperature. Check the level of engine coolant
1 in the reserve tank. When the engine is running
K0000029A
and the engine coolant is at normal
Figure 4-20 temperature, the coolant level in the reserve
tank should be at or neat the FULL (HOT) mark
(Figure 4-20, (6)). If the coolant is not at the
FULL (HOT) mark, add coolant to the reserve
tank to bring the coolant level to the FULL
(HOT) mark.

1 043925-00X02

Figure 4-21

86E-7 – 98E-7 Series 4-25

GENERAL SERVICE INFORMATION Engine Coolant

Daily Check of the Cooling System

1. Check the level of engine coolant in the reserve
tank. When the engine is cold, the coolant level
in the tank should be at or slightly above the
LOW (COLD) mark (Figure 4-20, (4)) on the
coolant reserve tank.
If the coolant level is at the FULL (HOT) mark
(Figure 4-20, (6)) when the engine is cold, the
coolant will expand when it becomes hot and
possibly spray out of the overflow hose.
2. Add additional engine coolant to the reserve
tank if necessary.
3. Check the radiator hoses for cracks, abrasions,
cuts or other damage. Replace as necessary.

Engine Coolant Capacity (Typical)

Capacities listed are for the engine only without a
radiator. Refer to the operation manual for actual
engine coolant capacity on your machine.
The following are the engine coolant capacities for
various engines.

Engine model Engine coolant capacity

3D88E-7, S3D86E-7 2.1 qt (2.0 l)
4D88E-7, S4D86E-7 2.9 qt (2.7 l)
4D98E-7, S4D98E-7 4.4 qt (4.2 l)

4-26 86E-7 – 98E-7 Series

Specifications GENERAL SERVICE INFORMATION

SPECIFICATIONS
Description of Model Number
S 3 D 86 E - 7

Model

Common rail system (EPA Tier4 certified)

Cylinder bore (mm)

Diesel engine

No. of cylinders

Turbocharged (No symbol indicates naturally aspirated)

Engine General Specifications

Type Vertical in-line, water cooled, 4-cycle diesel engine
Fuel injection system Common rail system
Starting system Electric starting
Cooling system Radiator
Lubricating system Forced lubrication with trochoid pump
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end

Note:
• The information described in Principal Engine Specifications is for a “standard” engine. To obtain the
information for the engine installed in your driven machine, please refer to the manual provided by the
driven machine manufacturer.
• Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
• Atmospheric condition: Room temperature 77 °F (25 °C), atmospheric pressure 29.53 in. Hg (100 kPa,
750 mm Hg), relative humidity 30 %
• Fuel temperature at fuel injector pump inlet: 104 °F (40 °C)
• Fuel feeding pressure: 20 ± 10 kPa (net) after engine break-in has been performed with the cooling fan,
air cleaner and muffler installed to the engine.
• With cooling fan, air cleaner, muffler:
• After the engine break-in period. Output allowable deviation: ± 3 %
• 1 PS = 0.7355 kW
• 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW

86E-7 – 98E-7 Series 4-27

GENERAL SERVICE INFORMATION Specifications

Engine Speed Specifications

VH: Variable High Speed specification
VM: Variable Medium Speed specification
CH: Constant High Speed specification
CL: Constant Low Speed specification

4-28 86E-7 – 98E-7 Series

Principal Engine Specifications GENERAL SERVICE INFORMATION

PRINCIPAL ENGINE SPECIFICATIONS

3D88E-7
Engine model 3D88E-7
Version VM
Type Vertical in-line diesel engine (Common rail system)
Combustion system Direct injection
Aspiration Naturally aspiration
No. of cylinders 3
Bore × stroke 88 × 90 mm
Displacement 1.642 l
3000 min-1
Max. rated output
27.5 kW
(Gross)
37.4 PS
High idling 3150 ± 25 min-1
Engine weight (Dry) 188 kg
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end
Cooling system Liquid-cooled with radiator
Lubricating system Forced lubrication with trochoid pump
Normal oil pressure at
0.34 - 0.54 MPa
rated engine speed
Normal oil pressure at
0.06 MPa
low idle speed
Electric starting (Starter motor: DC 12 V - 1.7 kW)
Starting system Alternator (12 V - 55 A)
Recommended battery capacity: 12 V 413CCA
Dimensions (L × W × H) Depend on KDPF layout
6.7/3.9 l
Engine oil pan capacity
(Dipstick upper limit/lower limit)
Engine coolant capacity 2.0 l (Engine only)
Standard cooling fan ø335 pusher
Crank V-pulley dia./
ø110/ø110 mm
fan V-pulley dia.
Top clearance 0.73 ± 0.06 mm

86E-7 – 98E-7 Series 4-29

GENERAL SERVICE INFORMATION Principal Engine Specifications

S3D86E-7
Engine model S3D86E-7
Version VM
Type Vertical in-line diesel engine (Common rail system)
Combustion system Direct injection
Aspiration Turbocharged
No. of cylinders 3
Bore × stroke 86 × 90 mm
Displacement 1.568 l
3000 min-1
Max. rated output
32.4 kW
(Gross)
44.1 PS
High idling 3150 ± 25 min-1
Engine weight (Dry) 200 kg
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end
Cooling system Liquid-cooled with radiator
Lubricating system Forced lubrication with trochoid pump
Normal oil pressure at
0.34 - 0.54 MPa
rated engine speed
Normal oil pressure at
0.06 MPa
low idle speed
Electric starting (Starter motor: DC 12 V - 1.7 kW)
Starting system Alternator (12 V - 55 A)
Recommended battery capacity: 12 V 413CCA
Dimensions (L × W × H) Depend on KDPF layout
6.7/3.9 l
Engine oil pan capacity
(Dipstick upper limit/lower limit)
Engine coolant capacity 2.0 l (Engine only)
Standard cooling fan ø350 pusher
Crank V-pulley dia./
ø110/ø110 mm
fan V-pulley dia.
Top clearance 0.73 ± 0.06 mm

4-30 86E-7 – 98E-7 Series

Principal Engine Specifications GENERAL SERVICE INFORMATION
4D88E-7
Engine model 4D88E-7
Version VM
Type Vertical in-line diesel engine (Common rail system)
Combustion system Direct injection
Aspiration Naturally aspiration
No. of cylinders 4
Bore × stroke 88 × 90 mm
Displacement 2.189 l
3000 min-1
Max. rated output
35.5 kW
(Gross)
48.3 PS
High idling 3150 ± 25 min-1
Engine weight (Dry) 220 kg
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end
Cooling system Liquid-cooled with radiator
Lubricating system Forced lubrication with trochoid pump
Normal oil pressure at
0.32 - 0.47 MPa
rated engine speed
Normal oil pressure at
0.06 MPa
low idle speed
Electric starting (Starter motor: DC 12 V - 1.7 kW)
Starting system Alternator (12 V - 55 A)
Recommended battery capacity: 12 V 622CCA
Dimensions (L × W × H) Depend on KDPF layout
7.4/4.0 l
Engine oil pan capacity
(Dipstick upper limit/lower limit)
Engine coolant capacity 2.7 l (Engine only)
Standard cooling fan ø370 pusher
Crank V-pulley dia./
ø110/ø110 mm
fan V-pulley dia.
Top clearance 0.73 ± 0.06 mm

86E-7 – 98E-7 Series 4-31

GENERAL SERVICE INFORMATION Principal Engine Specifications

S4D86E-7
Engine model S4D86E-7
Version VM
Type Vertical in-line diesel engine (Common rail system)
Combustion system Direct injection
Aspiration Turbocharged
No. of cylinders 4
Bore × stroke 86 × 90 mm
Displacement 2.090 l
3000 min-1
Max. rated output
44.0 kW
(Gross)
59.8 PS
High idling 3150 ± 25 min-1
Engine weight (Dry) 225 kg
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end
Cooling system Liquid-cooled with radiator
Lubricating system Forced lubrication with trochoid pump
Normal oil pressure at
0.36 - 0.51 MPa
rated engine speed
Normal oil pressure at
0.06 MPa
low idle speed
Electric starting (Starter motor: DC 12 V - 1.7 kW)
Starting system Alternator (12 V - 55 A)
Recommended battery capacity: 12 V 622CCA
Dimensions (L × W × H) Depend on KDPF layout
7.4/4.0 l
Engine oil pan capacity
(Dipstick upper limit/lower limit)
Engine coolant capacity 2.7 l (Engine only)
Standard cooling fan ø370 pusher
Crank V-pulley dia./
ø110/ø110 mm
fan V-pulley dia.
Top clearance 0.73 ± 0.06 mm

4-32 86E-7 – 98E-7 Series

Principal Engine Specifications GENERAL SERVICE INFORMATION
4D98E-7
Engine model 4D98E-7
Version VM
Type Vertical in-line diesel engine (Common rail system)
Combustion system Direct injection
Aspiration Naturally aspiration
No. of cylinders 4
Bore × stroke 98 × 110 mm
Displacement 3.319 l
2500 min-1
Max. rated output
51.7 kW
(Gross)
70.3 PS
High idling 2650 ± 25 min-1
Engine weight (Dry) 280 kg
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end
Cooling system Liquid-cooled with radiator
Lubricating system Forced lubrication with trochoid pump
Normal oil pressure at
0.29 - 0.39 MPa
rated engine speed
Normal oil pressure at
0.06 MPa
low idle speed
Electric starting (Starter motor: DC 12 V - 3.0 kW)
Starting system Alternator (DC12 V - 55 A)
Recommended battery capacity: 12 V 799CCA
Dimensions (L × W × H) Depend on KDPF layout
10.5/6.0 l
Engine oil pan capacity
(Dipstick upper limit/lower limit)
Engine coolant capacity 4.2 l (Engine only)
Standard cooling fan ø430 pusher
Crank V-pulley dia./
ø130/ø130 mm
fan V-pulley dia.
Top clearance 0.793 ± 0.063 mm

86E-7 – 98E-7 Series 4-33

GENERAL SERVICE INFORMATION Principal Engine Specifications

S4D98E-7
Engine model S4D98E-7
Version VM
Type Vertical in-line diesel engine (Common rail system)
Combustion system Direct injection
Aspiration Turbocharged
No. of cylinders 4
Bore × stroke 94 × 110 mm
Displacement 3.053 l
2500 min-1
Max. rated output
53.7 kW
(Gross)
73.0 PS
High idling 2650 ± 25 min-1
Engine weight (Dry) 291 kg
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end
Cooling system Liquid-cooled with radiator
Lubricating system Forced lubrication with trochoid pump
Normal oil pressure at
0.29 - 0.39 MPa
rated engine speed
Normal oil pressure at
0.06 MPa
low idle speed
Electric starting (Starter motor: DC 12 V - 3.0 kW)
Starting system Alternator (DC12 V - 55 A)
Recommended battery capacity: 12 V 799CCA
Dimensions (L × W × H) Depend on KDPF layout
10.5/6.0 l
Engine oil pan capacity
(Dipstick upper limit/lower limit)
Engine coolant capacity 4.2 l (Engine only)
Standard cooling fan ø430 pusher
Crank V-pulley dia./
ø130/ø130 mm
fan V-pulley dia.
Top clearance 0.793 ± 0.071 mm

4-34 86E-7 – 98E-7 Series

Principal Engine Specifications GENERAL SERVICE INFORMATION
Set Output Listed by Rotation
Gross output (kW)
Model Displacement
2000 2100 2200 2300 2400 2500 2600 2700 2800 3000
3D88E-7 1.642 – – – – 21.8 22.8 23.7 24.6 25.5 27.5
S3D86E-7 1.568 – – – – – 27.4 28.5 – 31.0 32.4
4D88E-7 2.189 24.2 25.4 26.7 27.9 29.1 30.5 31.7 33.0 34.3 35.5
S4D86E-7 2.091 – – – – 35.5 36.6 37.9 39.5 41.1 44.0
4D98E-7 3.318 42.4 44.3 46.2 48.1 49.9 51.7 – – – –
S4D98E-7 3.318 51.6 53.7 53.7 53.7 53.7 53.7 – – – –

86E-7 – 98E-7 Series 4-35

GENERAL SERVICE INFORMATION Engine Service Standards

ENGINE SERVICE STANDARDS

Reference
Inspection item Standard Limit
page
See Measuring
and Adjusting
0.006 - 0.010 in.
Intake/exhaust valve clearance All models – Valve
(0.15 - 0.25 mm)
Clearance on
page 6-42
455 - 485 psi 355 - 385 psi
3D88E-7, 4D88E-7 (3.14 - 3.34 MPa; (2.45 - 2.65 MPa;
32 - 34 kgf/cm²) 25 - 27 kgf/cm²)
Compression 411 - 441 psi 340 - 370 psi
pressure at S3D86E-7, S4D86E-7 (2.84 - 3.04 MPa; (2.35 - 2.55 MPa; –
250 min-1 (rpm) 29 - 31 kgf/cm²) 24 - 26 kgf/cm²)
484 - 513 psi 384 - 414 psi
4D98E-7, S4D98E-7 (3.33 - 3.53 MPa; (2.65 - 2.85 MPa;
34 - 36 kgf/cm²) 27 - 29 kgf/cm²)
29 - 43 psi
Deviation between cylinders All models (0.2 - 0.3 MPa; – –
2 - 3 kgf/cm²)
5.8 - 8.8 psi
Oil pressure switch operating pressure (0.04 - 0.06 MPa; – –
0.4 - 0.6 kgf/cm²)
Valve opening Full opening lift
temperature temperature
0.32 in. (8 mm) or
157 °F - 163 °F See
All models above
Thermostat (70 °C - 73 °C) Thermostat on
185 °F (85 °C)
page 8-9
0.39 in. (10 mm)
All models 176 °F - 183 °F
or above
option (80 °C - 84 °C)
203 °F (95 °C)
See
225 °F - 235 °F Temperature
Coolant temperature switch –
(107 °C - 113 °C) switch on
page 8-8

4-36 86E-7 – 98E-7 Series

Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION

TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS

Use the correct amount of torque when you tighten the fasteners on the machine. Applying excessive torque
may damage the fastener or component and not enough torque may cause a leak or component failure.

NOTICE
The tightening torque in the Standard Torque Chart (see General Service Information section) should be
applied only to the bolts with a “7” head. (JIS strength classification: 7T)
• Apply 60 % torque to bolts that are not listed.
• Apply 80 % torque when tightened to aluminum alloy.

Nominal thread
Item × pitch Tightening torque Remarks
diameter
7 - 9 ft-lb (87 -104 in.-lb,
M6 × 1.0 mm 9.8 -11.8 N·m, 1.0 -1.2 kgf·m)

M8 × 1.25 mm 17 - 21 ft-lb (200 - 251 in.-lb,

22.6 - 28.4 N·m, 2.3 - 2.9 kgf·m) Use 80 % of the value at
33 - 40 ft-lb left when the tightening
M10 × 1.5 mm
Hexagon bolt (44.1 - 53.9 N·m, 4.5 - 5.5 kgf·m) part is aluminum.
(7T) and nut 58 - 72 ft-lb Use 60 % of the value at
M12 × 1.75 mm (78.4 - 98.0 N·m, 8.0 - 10 kgf·m) left for 4T bolts and lock
94 - 108 ft-lb nuts.
M14 × 1.5 mm
(127.5 - 147.1 N·m, 13 - 15 kgf·m)
159 - 174 ft-lb
M16 × 1.5 mm
(215.7- 235.4 N·m, 22 - 24 kgf·m)
7 ft-lb
1/8 (87 in.-lb, 9.8 N·m, 1.0 kgf·m)

1/4 14 ft-lb
(173 in.-lb, 19.6 N·m, 2.0 kgf·m)
PT plug –
3/8 22 ft-lb
(29.4 N·m, 3.0 kgf·m)
43 ft-lb
1/2
(58.8 N·m, 6.0 kgf·m)
9 - 12 ft-lb (112 - 148 in.-lb,
M8 12.7 - 16.7 N·m, 1.3 - 1.7 kgf·m)

M10 14 - 19 ft-lb (173 - 225 in.-lb,

19.6 - 25.4 N·m, 2.0 - 2.5 kgf·m)
18 - 25 ft-lb
Pipe joint bolt M12 –
(24.5 - 34.3 N·m, 2.5 - 3.5 kgf·m)
29 - 36 ft-lb
M14 (39.2 - 49.0 N·m, 4.0 - 5.0 kgf·m)

M16 36 - 43 ft-lb
(49.0 - 58.8 N·m, 5.0 - 6.0 kgf·m)
Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.

86E-7 – 98E-7 Series 4-37

GENERAL SERVICE INFORMATION Abbreviations and Symbols

ABBREVIATIONS AND SYMBOLS

■ Abbreviations k kelvin
kg kilogram
A ampere kilogram force per square
AC alternating current kgf/cm²
centimeter
Association des Constructeurs kgf/m kilogram force per meter
ACEA
Européens d’Automobilies km kilometers
Ah ampere-hour kPa kilopascal
API American Petroleum Institute kW kilowatt
ARB Air Resources Board l liter
ATDC after top dead center l/hr liter per hour
BDC bottom dead center lb pound
BTDC before top dead center lbf pound force
°C degree Celsius m meter
CARB California Air Resources Board ml milliliter
CCA cold cranking amp mm millimeter
cfm cubic feet per minute mmAq millimeter Aqueous (water)
cm centimeter MPa megapascal
cm³ cubic centimeter mV millivolt
cm³/min cubic centimeter per minute N newton
cu in. cubic inch N·m newton meter
D diameter No. number
DC direct current O.D. outside diameter
DI direct injection oz ounce
DVA direct volt adapter Pa pascal
EPA Environmental Protection Agency PS horsepower (metric)
ESG electronic speed governor PSI pound per square inch
°F degree Fahrenheit qt quart (U.S.)
fl oz fluid ounce (U.S.) R radius
fl oz/min fluid ounce (U.S.) per minute rpm revolutions per minute
ft foot SAE Society of Automotive Engineers
ft-lb foot pound sec. second
ft-lbf/min foot pound force per minute t short ton 2000 lb
g gram TBN total base number
gal gallon (U.S.) TDC top dead center
gal/hr gallon (U.S.) per hour V volt
gal/min gallon (U.S.) per minute VAC volt alternating current
GL gear lubricant VDC volt direct current
hp horsepower (U.S.) W watt
hr hour
I.D. inside diameter ■ Symbols
ID identification
IDI indirect injection ° degree
in. inch + plus
in.Aq inches Aqueous (water) - minus
in.Hg inches Mercury ± plus or minus
in.-lb inch pound  ohm
j joule  micro
Japanese Automobile Standards % percent
JASO
Organization

4-38 86E-7 – 98E-7 Series

Unit Conversions GENERAL SERVICE INFORMATION

UNIT CONVERSIONS
■ Unit prefixes ■ Units of torque
Prefix Symbol Power ft-lb × 1.3558 = N·m
mega M × 1,000,000 ft-lb × 0.1383 = kgf/m
kilo k × 1,000 in.-lb × 0.1130 = N·m
centi c × 0.01 in.-lb × 0.0115 = kgf/m
milli m × 0.001 kgf/m × 7.2330 = ft-lb
micro  × 0.000001 kgf/m × 86.8000 = in.-lb
kgf/m × 9.8070 = N·m
■ Units of length N·m × 0.7376 = ft-lb
N·m × 8.8510 = in.-lb
mile × 1.6090 = km
N·m × 0.1020 = kgf/m
ft × 0.3050 =m
in. × 2.5400 = cm ■ Units of pressure
in. × 25.4000 = mm
km × 0.6210 = mile PSI × 0.0689 = bar
m × 3.2810 = ft PSI × 6.8950 = kPa
cm × 0.3940 = in. PSI × 0.0703 = kg/cm²
mm × 0.0394 = in. bar × 14.5030 = PSI
bar × 100.0000 = kPa
■ Units of volume bar × 29.5300 = inHg (60 °F)
gal (U.S.) × 3.78540 =l kPa × 0.1450 = PSI
qt (U.S.) × 0.94635 =l kPa × 0.0100 = bar
cu in. × 0.01639 =l kPa × 0.0102 = kg/cm²
cu in. × 16.38700 = ml kg/cm² × 98.0700 = PSI
fl oz (U.S.) × 0.02957 =l kg/cm² × 0.9807 = bar
fl oz (U.S.) × 29.57000 = ml kg/cm² × 14.2200 = kPa
cm³ × 1.00000 = ml in.Hg (60°) × 0.0333 = bar
cm³ × 0.03382 = fl oz (U.S.) in.Hg (60°) × 3.3770 = kPa
in.Hg (60°) × 0.0344 = kg/cm²
■ Units of mass mmAq × 0.0394 = in.Aq

lb × 0.45360 = kg ■ Units of power

oz × 28.35000 =g
kg × 2.20500 = lb hp (metric or × 0.9863201 = hp SAE
g × 0.03527 = oz PS)
hp (metric or × 0.7354988 = kW
■ Units of force PS)
hp SAE × 1.0138697 = hp (metric or PS)
lbf × 4.4480 =N hp SAE × 0.7456999 = kW
lbf × 0.4536 = kgf kW × 1.3596216 = hp (metric or PS)
N × 0.2248 = lbf kW × 1.3410221 = hp SAE
N × 0.1020 = kgf
kgf × 2.2050 = lbf ■ Units of temperature
kgf × 9.8070 =N
°F = (1.8 × °C) + 32
°C = 0.556 × (°F - 32)

86E-7 – 98E-7 Series 4-39

GENERAL SERVICE INFORMATION Unit Conversions

4-40 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 5

PERIODIC
MAINTENANCE
Page
Before You Begin Servicing ................................................................... 5-3
Introduction............................................................................................. 5-4
The Importance of Periodic Maintenance......................................... 5-4
Performing Periodic Maintenance .................................................... 5-4
Replacement Parts........................................................................... 5-4
Required EPA/ARB Maintenance USA Only.................................... 5-4
EPA/ARB Installation Requirements USA Only ............................... 5-4
Periodic Maintenance Schedule............................................................. 5-5
Periodic Maintenance Procedures ......................................................... 5-6
Every 1000 Hours of Operation........................................................ 5-6
Every 1500 Hours of Operation........................................................ 5-6
Every 2000 Hours of Operation........................................................ 5-7
Every 3000 Hours of Operation........................................................ 5-8
Every 6000 Hours of Operation........................................................ 5-9

86E-7 – 98E-7 Series 5-1

PERIODIC MAINTENANCE

5-2 86E-7 – 98E-7 Series

 Before You Begin Servicing PERIODIC MAINTENANCE

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.

86E-7 – 98E-7 Series 5-3

PERIODIC MAINTENANCE Introduction

INTRODUCTION Replacement Parts

This section describes the procedures for proper Komatsu recommends that you use genuine parts
care and maintenance of the engine. when replacement parts are needed. Genuine
replacement parts help ensure long engine life.
The Importance of Periodic
Maintenance Required EPA/ARB Maintenance USA
Only
Engine deterioration and wear occurs in proportion
to length of time the engine has been in service and To maintain optimum engine performance and
the conditions the engine is subject to during compliance with the Environmental Protection
operation. Periodic maintenance prevents Agency (EPA) Regulations Non-Road Engines and
unexpected downtime, reduces the number of the California Air Resources Board (ARB,
accidents due to poor machine performance and California), it is essential that you follow the
helps extend the life of the engine. Periodic Maintenance Schedule on page 5-5 and
Periodic Maintenance Procedures on page 5-6.
Performing Periodic Maintenance
EPA/ARB Installation Requirements
WARNING USA Only
Exhaust hazard! The following are the installation requirements for
• Never operate the engine in an the EPA/ARB. Unless these requirements are met,
enclosed area such as a garage, the exhaust gas emissions will not be within the
tunnel, underground room, limits specified by the EPA and ARB.
manhole or ship’s hold without
proper ventilation. ■ Maximum exhaust gas restriction shall
be:
• Never block windows, vents, or other means
of ventilation if the engine is operating in an Initial upper limit 12.7 kPa (1300 mmAq)
enclosed area. All internal combustion Cleaning upper limit 45 kPa (4590 mmAq)
engines create carbon monoxide gas during
operation. Accumulation of this gas within an Maximum air intake restriction shall be 0.90 psi
enclosure could cause illness or even death. (6.23 kPa; 635 mmAq) or less. Clean or replace the
• Make sure that all connections are tightened air cleaner element if the air intake restriction
to specifications after repair is made to the exceeds the above mentioned value.
exhaust system.
• Failure to comply could result in death or
serious injury.

Perform periodic maintenance procedures in an

open, level area free from traffic. If possible,
perform the procedures indoors to prevent
environmental conditions, such as rain, wind, or
snow, from damaging the machine.

5-4 86E-7 – 98E-7 Series

 Periodic Maintenance Schedule PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

Daily and periodic maintenance is important to keep the engine in good operating condition. The following
is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary
depending on engine application, loads, diesel fuel and engine oil used and are hard to establish
definitively. The following should be treated only as a general guideline.

NOTICE
Establish a periodic maintenance plan according to the engine application and make sure you perform the
required periodic maintenance at the intervals indicated. Failure to follow these guidelines will impair the
engine’s safety and performance characteristics, shorten the engine’s life and may affect the warranty
coverage on your engine.
This series engines may inject fuel after general combustion for the purpose of self-regeneration of the
KDPF. This fuel may enter the oil pan through the cylinder and dilute the engine oil.
Check the oil level daily. If it is above the upper limit of the dipstick, change the oil regardless of the
replacement intervals.
For the items marked with ●, the specialized knowledge and skill are particularly required. Have your
authorized dealer or distributor perform maintenance according to this manual.

●: Have your authorized dealer or distributor perform checking and cleaning

Periodic maintenance interval

System Check item Daily Every Every Every Every Every Every Every Every
50 250 500 1000 1500 2000 3000 6000
hours hours hours hours hours hours hours hours
Check and adjust intake/exhaust
●
Cylinder valve clearance
head Lap intake/exhaust valve seats
●
(if required)
Inspect turbocharger (blower
●
wash as necessary)
Inspect, clean and test EGR valve ●
Clean EGR lead valve ●
Clean EGR cooler
Emission ●
(clean to blow water/air passages)
control
warranty Inspect crankcase breather
●
system
Check and clean of KDPF soot
●*1
filter
Inspect and test intake throttle
●
valve

*1: If your engine is equipped with KDPF cleaning alarm, clean the KDPF when the alarm lamp comes on.
If your engine is not equipped with KDPF cleaning alarm, clean the KDPF every 6000 hrs of operation.

Note: These procedures are considered normal maintenance and are performed at the owner’s expense.

86E-7 – 98E-7 Series 5-5

PERIODIC MAINTENANCE Periodic Maintenance Procedures

PERIODIC MAINTENANCE PROCEDURES

Every 1000 Hours of Operation Every 1500 Hours of Operation

Perform the following maintenance every 1000 Perform the following maintenance every 1500
hours of operation. hours of operation.
• Adjust intake/exhaust valve clearance (if • Inspect crankcase breather system
required)
■ Inspect crankcase breather system
■ Check and adjust intake/exhaust valve Proper operation of the crankcase breather system
clearance is required to maintain the emission requirements
For the check method of intake/exhaust valve of the engine. The EPA/ARB requires that the
clearance, see Measuring and Adjusting Valve crankcase breather system is inspected every 1500
Clearance on page 6-42. For the standard values hours.
and limit values, see Cylinder Head Specifications
There are three different crankcase breather
on page 6-4.
systems used on this series engines. Only the non-
To maintain the correct timing for opening and turbo engines crankcase breather system requires
closing the intake/exhaust valves, it is necessary to periodic maintenance.
adjust the intake/exhaust valve clearance in proper
The non-turbo engines use a crankcase breather
procedure. Improper adjustment increases the
system that has a spring-backed diaphragm
engine noise, and causes poor performance and
(Figure 5-1, (1)) in the valve cover
engine damage. See Intake/Exhaust Valve and
(Figure 5-1, (2)). When the crankcase pressure
Guide on page 6-5.
reaches a predetermined value, the diaphragm
opens a passage that allows crankcase fumes to
be routed to the intake manifold.
To inspect the diaphragm and spring
(Figure 5-1, (3)):
1. Remove the bolts retaining the diaphragm
cover (Figure 5-1, (4)).

5-6 86E-7 – 98E-7 Series

 Periodic Maintenance Procedures PERIODIC MAINTENANCE

4 Every 2000 Hours of Operation

3
Perform the following maintenance every 2000
5 hours of operation.

1 • Lap the intake and exhaust valves (if required)

2 ■ Lap the intake and exhaust valves
Adjustment is necessary to maintain proper contact
of the valves and seats. For lapping of the intake
and exhaust valves, see Inspection of intake and
exhaust valves on page 6-35.

K0002135

Figure 5-1
2. Remove the diaphragm cover, spring,
diaphragm plate (Figure 5-1, (5)) and
diaphragm.
3. Inspect the diaphragm for tears. Inspect the
spring for distortion. Replace components if
necessary.
4. Reinstall the diaphragm, diaphragm plate,
spring and diaphragm cover. Tighten the
diaphragm bolts to specified torque.
Failure of the diaphragm and/or spring will cause
the loss of pressure control and allow an excessive
amount of crankcase fumes to be routed to the
intake manifold. This could result in excessive
deposits in the intake system, high engine exhaust
smoke levels, excessive engine oil consumption,
and/or engine run-on due to the burning of the
engine oil.

86E-7 – 98E-7 Series 5-7

PERIODIC MAINTENANCE Periodic Maintenance Procedures

■ Inspect and clean EGR lead valve

Every 3000 Hours of Operation
The EGR lead valve is located in the passage of
recirculated gas.
Perform the following maintenance every 3000
hours of operation. To prevent carbon accumulation in or clogging of
the lead valve, inspect and clean the lead valve at
• Inspect turbocharger (blower wash as regular intervals. For cleaning of the EGR lead
necessary) valve, see Clean Lead Valves on page 6-76.
S3D86E-7, S4D86E-7, S4D98E-7
• Inspect, clean and test EGR valve EGR valve
EGR lead valve
• Inspect and clean EGR lead valve
• Check and clean injector
• Inspect and test intake throttle valve
• Clean EGR cooler

■ Inspect turbocharger (blower wash as

necessary)
S3D86E-7, S4D86E-7, S4D98E-7
Turbocharger service is required by the EPA/ARB
every 3000 hours. Your authorized dealer or EGR cooler
distributor will inspect and blower wash the unit if
necessary. If you notice that the engine seems
sluggish or the exhaust color is abnormal never 042183-00E00
wait until the next periodic interval. For cleaning
and inspection of the turbocharger, see Washing Figure 5-2
Procedure on page 10-10 and Periodic Inspection
on page 10-11. ■ Check and clean injector
Check the injector tip. Clean the injector tip with a
■ Inspect, clean and test EGR valve soft brush or replace it if necessary.
The EGR valve is a key component for cleaning
exhaust gas. ■ Inspect and test intake throttle valve
To prevent the valve from deteriorating in exhaust The intake throttle can affect the exhaust gas
gas recirculation performance due to carbon treatment performance. Therefore periodic
accumulation, inspect, clean and test the valve at maintenance of the intake throttle is required every
least every 3000 hours. For cleaning and 3000 hours of operation. For operational inspection
inspection of the EGR valve, see Cleaning the EGR of the intake throttle valve, see Intake Throttle on
Valves on page 6-75. page 6-78.

5-8 86E-7 – 98E-7 Series

 Periodic Maintenance Procedures PERIODIC MAINTENANCE
■ Clean EGR cooler
Every 6000 Hours of Operation
The EGR cooler is apt to be contaminated with rust
and scale that deteriorate the cooling performance.
Carbon accumulation in the exhaust gas passage Perform the following maintenance every 6000
of the cooler hinders circulation of exhaust gas, hours of operation.
resulting in deterioration in exhaust gas cleanup • Check and clean of KDPF soot filter
performance.
■ Check and clean of KDPF soot filter
To prevent such a problem, clean the cooler at least
every 3000 hours. If your engine is equipped with KDPF cleaning
alarm, clean the KDPF when the alarm lamp comes
For cleaning of the EGR cooler, see Clean EGR on. If your engine is not equipped with KDPF
Cooler on page 6-76. cleaning alarm, clean the KDPF every 6000 hrs of
operation.

86E-7 – 98E-7 Series 5-9

PERIODIC MAINTENANCE Periodic Maintenance Procedures

5-10 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 6

ENGINE
Page
Before You Begin Servicing ................................................................... 6-3
Introduction............................................................................................. 6-4
Cylinder Head Specifications ................................................................. 6-4
Adjustment Specifications ................................................................ 6-4
Cylinder Head................................................................................... 6-4
Intake/Exhaust Valve and Guide ...................................................... 6-5
Push Rod.......................................................................................... 6-6
Rocker Arm and Shaft ...................................................................... 6-6
Valve Spring ..................................................................................... 6-6
Camshaft and Timing Gear Train Specifications.................................... 6-7
Camshaft .......................................................................................... 6-7
Idler Gear Shaft and Bushing ........................................................... 6-8
Timing Gear Backlash ...................................................................... 6-8
Crankshaft and Piston Specifications..................................................... 6-9
Crankshaft ........................................................................................ 6-9
Thrust Bearing................................................................................ 6-10
Piston ............................................................................................. 6-10
Piston Ring ..................................................................................... 6-11
Connecting Rod.............................................................................. 6-14
Tappet ............................................................................................ 6-15
Cylinder Block Specifications ............................................................... 6-16
Cylinder Block ................................................................................ 6-16
Special Torque Chart ........................................................................... 6-17
Torque for Bolts and Nuts .............................................................. 6-17
Special Service Tools........................................................................... 6-20
Measuring Instruments......................................................................... 6-24
Cylinder Head....................................................................................... 6-26
Cylinder Head Components ........................................................... 6-26

86E-7 – 98E-7 Series 6-1

ENGINE
Disassembly of Cylinder Head ........................................................6-28
Cleaning of Cylinder Head Components.........................................6-33
Inspection of Cylinder Head Components.......................................6-33
Reassembly of Cylinder Head.........................................................6-37
Measuring and Adjusting Valve Clearance ...........................................6-42
Crankshaft and Camshaft Components ................................................6-44
Disassembly of Engine....................................................................6-45
Disassembly of Camshaft and Timing Components .......................6-46
Disassembly of Crankshaft and Piston Components ......................6-50
Inspection of Crankshaft and Camshaft Components.....................6-53
Honing and Boring ..........................................................................6-60
Reassembly of Crankshaft and Piston Components.......................6-61
Reassembly of Camshaft and Timing Components ........................6-66
Final Reassembly of Engine ...........................................................6-69
EGR System .........................................................................................6-70
EGR System (Typical Model)..........................................................6-70
Typical Model for Turbocharger Model ...........................................6-71
Disassembly of Supply Pump .........................................................6-72
Cleaning the EGR Valves ...............................................................6-75
Clean Lead Valves ..........................................................................6-76
Precautions for Installation..............................................................6-76
Clean EGR Cooler ..........................................................................6-76
EGR Pipe and Other Connecting Elbows .......................................6-77
Installing EGR Related Components/Parts .....................................6-77
Intake Throttle .......................................................................................6-78
Precautions for Handling the Intake Throttle...................................6-78

6-2 86E-7 – 98E-7 Series

 Before You Begin Servicing ENGINE

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.

86E-7 – 98E-7 Series 6-3

ENGINE Introduction

INTRODUCTION
This section describes servicing of the engine.

CYLINDER HEAD SPECIFICATIONS

Adjustment Specifications
Model Valve clearance
All models 0.006 - 0.010 in. (0.15 - 0.25 mm)

Cylinder Head
Reference
Inspection item Standard Limit
page
0.0020 in. 0.0059 in.
Combustion surface distortion (flatness)
(0.05 mm) or less (0.15 mm)
0.0118 - 0.0197 in. 0.0315 in.
Intake
3D88E-7, S3D86E-7, (0.30 - 0.50 mm) (0.8 mm)
4D88E-7, S4D86E-7 See Valve
0.0118 - 0.0197 in. 0.0315 in.
Exhaust recession on
(0.30 - 0.50 mm) (0.8 mm)
Valve recession page 6-35.
0.0142 - 0.0220 in. 0.0315 in.
Intake
(0.36 - 0.56 mm) (0.8 mm)
4D98E-7, S4D98E-7
0.0138 - 0.0217 in. 0.0315 in.
Exhaust
(0.35 - 0.55 mm) (0.8 mm)
Intake 120° – See Valve face
Seat angle
Valve seat Exhaust 90° – and valve seat
Seat correction angle 40°, 150° – on page 6-36.

6-4 86E-7 – 98E-7 Series

 Cylinder Head Specifications ENGINE
Intake/Exhaust Valve and Guide
Reference
Inspection item Standard Limit
page
0.3154 - 0.3159 in. 0.3189 in.
Guide inside diameter
(8.010 - 8.025 mm) (8.10 mm)
Valve stem outside 0.3132 - 0.3140 in. 0.3110 in.
Intake
diameter (7.955 - 7.975 mm) (7.90 mm)
3D88E-7, 0.0014 - 0.0028 in. 0.0071 in.
Valve stem bend See Inspection
S3D86E-7, (0.035 - 0.070 mm) (0.18 mm)
of valve guides
4D88E-7, 0.3156 - 0.3161 in. 0.3189 in.
Guide inside diameter on page 6-34.
S4D86E-7 (8.015 - 8.030 mm) (8.10 mm)
Valve stem outside 0.3132 - 0.3134 in. 0.3110 in.
Exhaust
diameter (7.955 - 7.960 mm) (7.90 mm)
0.0018 - 0.0030 in. 0.0071 in.
Valve stem bend
(0.045 - 0.075 mm) (0.18 mm)
0.2756 - 0.2762 in. 0.2787 in.
Guide inside diameter
(7.000 - 7.015 mm) (7.08 mm)
Valve stem outside 0.2734 - 0.2740 in. 0.2717 in.
Intake
diameter (6.945 - 6.960 mm) (6.90 mm)
0.0016 - 0.0028 in. 0.0067 in.
Oil clearance See Inspection
4D98E-7, (0.040 - 0.070 mm) (0.17 mm)
of valve guides
S4D98E-7 0.2756 - 0.2762 in. 0.2787 in.
Guide inside diameter on page 6-34.
(7.000 - 7.015 mm) (7.08 mm)
Valve stem outside 0.2732 - 0.2738 in. 0.2717 in.
Exhaust
diameter (6.940 - 6.955 mm) (6.90 mm)
0.0018 - 0.0030 in. 0.0067 in.
Valve stem bend
(0.045 - 0.075 mm) (0.17 mm)
3D88E-7, S3D86E-7, See
Valve guide projection from 0.5791 - 0.5905 in.
4D88E-7, S4D86E-7, – Reassembly of
cylinder head (14.71 - 15.00 mm)
4D98E-7, S4D98E-7 valve guides on
Valve guide installation method Cold-fitted – page 6-37.
See
3D88E-7, S3D86E-7, Reassembly of
Valve stem seal projection from 0.736 - 0.748 in.
4D88E-7, S4D86E-7, – intake and
cylinder head (18.7 - 19.0 mm)
4D98E-7, S4D98E-7 exhaust valves
on page 6-38

86E-7 – 98E-7 Series 6-5

ENGINE Cylinder Head Specifications

Push Rod
Reference
Inspection item Standard Limit
page
See Push rod
Less than 0.0012 in.
Push rod bend - all models bend on
0.0012 in. (0.03 mm) (0.03 mm)
page 6-33.

Rocker Arm and Shaft

Reference
Model Inspection item Standard Limit
page
0.6299 - 0.6307 in. 0.6327 in.
Arm shaft hole diameter
3D88E-7, (16.000 - 16.020 mm) (16.07 mm)
S3D86E-7, 0.6286 - 0.6293 in. 0.6276 in.
Shaft outside diameter
4D88E-7, (15.966 - 15.984 mm) (15.94 mm)
S4D86E-7 0.0006 - 0.0021 in. 0.0051 in.
Oil clearance See Inspection
(0.016 - 0.054 mm) (0.13 mm) of rocker arm
0.7283 - 0.7291 in. 0.7311 in. assembly on
Arm shaft hole diameter page 6-34.
(18.500 - 18.520 mm) (18.57 mm)
4D98E-7, 0.7272 - 0.7280 in. 0.7260 in.
Shaft outside diameter
S4D98E-7 (18.470 - 18.490 mm) (18.44 mm)
0.0004 - 0.0020 in. 0.0051 in.
Oil clearance
(0.010 - 0.050 mm) (0.13 mm)

Valve Spring
Reference
Inspection item Model Standard Limit
page
1.6535 in. 1.6339 in.
3D88E-7, S3D86E-7, 4D88E-7, S4D86E-7
(42.0 mm) (41.5 mm)
Free length
1.8701 in. 1.8504 in.
4D98E-7, S4D98E-7 See Inspection
(47.5 mm) (47.0 mm)
of valve springs
0.0551 in. on page 6-36.
3D88E-7, S3D86E-7, 4D88E-7, S4D86E-7 –
(1.4 mm)
Squareness
0.0472 in.
4D98E-7, S4D98E-7 –
(1.2 mm)

6-6 86E-7 – 98E-7 Series

 Camshaft and Timing Gear Train Specifications ENGINE

CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS

Camshaft
Reference
Inspection item Standard Limit
page
See Removal of
0.0020 - 0.0079 in. 0.0118 in.
End play camshaft on
(0.05 - 0.20 mm) (0.030 mm)
page 6-48.
0 - 0.0008 in. 0.0020 in.
Bend (1/2 the dial gauge reading)
(0 - 0.02 mm) (0.05 mm)
See Inspection
3D88E-7, S3D86E-7, 1.5197 - 1.5276 in. 1.5098 in.
of camshaft on
4D88E-7, S4D86E-7 (38.600 - 38.800 mm) (38.350 mm)
Cam lobe height page 6-58.
1.6707 - 1.6758 in. 1.6608 in.
4D98E-7, S4D98E-7
(42.435 - 42.565 mm) (42.185 mm)
Shaft outside diameter/bearing inside diameter
1.7713 - 1.7738 in. 1.7768 in.
Bushing inside diameter
(44.990 - 45.055 mm) (45.130 mm)
1.7687 - 1.7697 in. 1.7673 in.
Gear end Camshaft outside diameter
(44.925 - 44.950 mm) (44.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil clearance
(0.040 - 0.130 mm) (0.240 mm)
1.7716 - 1.7726 in. 1.7756 in.
Bore inside diameter
3D88E-7, (45.000 - 45.025 mm) (45.100 mm)
See Inspection
S3D86E-7, 1.7681 - 1.7691 in. 1.7667 in.
Intermediate Camshaft outside diameter of camshaft on
4D88E-7, (44.910 - 44.935 mm) (44.875 mm)
page 6-58.
S4D86E-7 0.0026 - 0.0045 in. 0.0089 in.
Oil clearance
(0.065 - 0.115 mm) (0.225 mm)
1.7716 - 1.7726 in. 1.7756 in.
Bore inside diameter
(45.000 - 45.025 mm) (45.100 mm)
Flywheel 1.7687 - 1.7697 in. 1.7673 in.
Camshaft outside diameter
end (44.925 - 44.950 mm) (44.890 mm)
0.0020 - 0.0039 in. 0.0083 in.
Oil clearance
(0.050 - 0.100 mm) (0.210 mm)
1.9681 - 1.9707 in. 1.9736 in.
Bushing inside diameter
(49.990 - 50.055 mm) (50.130 mm)
1.9655 - 1.9665 in. 1.9642 in.
Gear end Camshaft outside diameter
(49.925 - 49.950 mm) (49.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil clearance
(0.040 - 0.130 mm) (0.240 mm)
1.9685 - 1.9695 in. 1.9724 in.
Bore inside diameter
(50.000 - 50.025 mm) (50.100 mm)
See Inspection
4D98E-7, 1.9650 - 1.9659 in. 1.9636 in.
Intermediate Camshaft outside diameter of camshaft on
S4D98E-7 (49.910 - 49.935 mm) (49.875 mm)
page 6-58.
0.0026 - 0.0045 in. 0.0089 in.
Oil clearance
(0.065 - 0.115 mm) (0.225 mm)
1.9685 - 1.9695 in. 1.9724 in.
Bore inside diameter
(50.000 - 50.025 mm) (50.100 mm)
Flywheel 1.9655 - 1.9665 in. 1.9642 in.
Camshaft outside diameter
end (49.925 - 49.950 mm) (49.890 mm)
0.0020 - 0.0039 in. 0.0083 in.
Oil clearance
(0.050 - 0.100 mm) (0.210 mm)

86E-7 – 98E-7 Series 6-7

ENGINE Camshaft and Timing Gear Train Specifications

Idler Gear Shaft and Bushing

Reference
Model Inspection item Standard Limit
page
1.8091 - 1.8100 in. 1.8071 in.
Shaft outside diameter
(45.950 - 45.975 mm) (45.900 mm)
1.8110 - 1.8120 in. 1.8140 in.
Idler gear A Bushing inside diameter
(46.000 - 46.025 mm) (46.075 mm)
3D88E-7, 0.0010 - 0.0030 in. 0.0068 in.
Oil clearance
S3D86E-7, (0.025 - 0.075 mm) (0.175 mm)
4D88E-7, 1.6909 - 1.6919 in. 1.6890 in.
S4D86E-7 Shaft outside diameter
(42.950 - 42.975 mm) (42.900 mm)
1.6929 - 1.6939 in. 1.6959 in.
Idler gear B Bushing inside diameter
(43.000 - 43.025 mm) (43.075 mm)
0.0010 - 0.0030 in. 0.0068 in.
Oil clearance
(0.025 - 0.075 mm) (0.175 mm)
1.8091 - 1.8100 in. 1.8071 in.
Shaft outside diameter
(45.950 - 45.975 mm) (45.900 mm)
1.8110 - 1.8120 in. 1.8140 in.
Idler gear A Bushing inside diameter
(46.000 - 46.025 mm) (46.075 mm)
0.0010 - 0.0030 in. 0.0068 in.
Oil clearance
4D98E-7, (0.025 - 0.075 mm) (0.175 mm)
S4D98E-7 1.8091 - 1.8100 in. 1.8071 in.
Shaft outside diameter
(45.950 - 45.975 mm) (45.900 mm)
1.8110 - 1.8120 in. 1.8140 in.
Idler gear B Bushing inside diameter
(46.000 - 46.025 mm) (46.075 mm)
0.0010 - 0.0030 in. 0.0068 in.
Oil clearance
(0.025 - 0.075 mm) (0.175 mm)

Timing Gear Backlash

Reference
Model Inspection item Standard Limit
page
See Checking
Crank gear, cam gear, idler gear, fuel 0.0031 - 0.0055 in. 0.0063 in. timing gear
All models
injection pump gear and PTO gear (0.08 - 0.14 mm) (0.16 mm) backlash on
page 6-46.

6-8 86E-7 – 98E-7 Series

 Crankshaft and Piston Specifications ENGINE

CRANKSHAFT AND PISTON SPECIFICATIONS

Crankshaft
Note: Check appropriate Parts Book for various sizes of replacement main bearing inserts.

Reference
Inspection item Standard Limit
page
0.0008 in.
Bend (1/2 the dial gauge reading) –
(0.02 mm)
1.8879 - 1.8883 in. 1.8859 in.
Journal outside diameter
(47.952 - 47.962 mm) (47.902 mm)
3D88E-7, 1.8898 - 1.8909 in.
Bearing inside diameter –
S3D86E-7, (48.000 - 48.026 mm)
4D88E-7, 0.0587 - 0.0591 in.
S4D86E-7 Bearing insert thickness –
(1.492 - 1.500 mm)
See Inspection
0.0015 - 0.0029 in. 0.0059 in.
Oil clearance of crankshaft on
Connecting rod (0.038 - 0.074 mm) (0.150 mm)
page 6-57.
journals 2.2816 - 2.2820 in. 2.2796 in.
Journal outside diameter
(57.952 - 57.962 mm) (57.902 mm)
2.2835 - 2.2845 in.
Bearing inside diameter –
4D98E-7, (58.000 - 58.026 mm)
S4D98E-7 0.0587 - 0.0591 in.
Bearing insert thickness –
(1.492 - 1.500 mm)
0.0015 - 0.0029 in. 0.0059 in.
Oil clearance
(0.038 - 0.074 mm) (0.150 mm)
1.9666 -1.9670 in. 1.9646 in.
Journal outside diameter
(49.952 - 49.962 mm) (49.902 mm)
3D88E-7, 1.9685 - 1.9693 in.
Bearing inside diameter –
S3D86E-7, (50.000 - 50.020 mm)
4D88E-7, 0.0785 - 0.0791 in.
S4D86E-7 Bearing insert thickness –
(1.995 - 2.010 mm)
0.0015 - 0.0027 in. 0.0059 in.
Oil clearance See Inspection
Main bearing (0.038 - 0.068 mm) (0.150 mm)
of crankshaft on
journal 2.5572 - 2.5576 in. 2.5552 in.
Journal outside diameter page 6-57.
(64.952 - 64.962 mm) (64.902 mm)
2.5590 - 2.5598 in.
Bearing inside diameter –
4D98E-7, (65.000 - 65.020 mm)
S4D98E-7 0.0785 - 0.0791 in.
Bearing insert thickness –
(1.995 - 2.010 mm)
0.0015 - 0.0027 in. 0.0059 in.
Oil clearance
(0.038 - 0.068 mm) (0.150 mm)

86E-7 – 98E-7 Series 6-9

ENGINE Crankshaft and Piston Specifications

Thrust Bearing
Reference
Inspection item Standard Limit
page
See Removal of
0.0051 - 0.0091 in. 0.0110 in.
Crankshaft end play - all models crankshaft on
(0.13 - 0.23 mm) (0.28 mm)
page 6-52.

Piston
Reference
Inspection item Standard Limit
page
3.4622 - 3.4634 in. 3.4604 in.
3D88E-7, 4D88E-7
(87.940 - 87.970 mm) (87.895 mm)
Piston outside diameter 3.3835 - 3.3846 in. 3.3817 in.
S3D86E-7, S4D86E-7 See Inspection
(Measure at 90° to the piston pin) (85.940 - 85.970 mm) (85.895 mm)
of pistons,
3.8559 - 3.8563 in. 3.8545 in.
4D98E-7, S4D98E-7 piston rings and
(97.940 - 97.950 mm) (97.905 mm)
wrist pin on
3D88E-7, S3D86E-7, 0.9449 in. page 6-54.
Piston diameter measure location –
4D88E-7, S4D86E-7 (24 mm)
(Upward from the bottom of the
piston) 0.8661 in.
4D98E-7, S4D98E-7 –
(22 mm)
1.0236 - 1.0240 in. 1.0252 in.
Hole inside diameter
3D88E-7, (26.000 - 26.009 mm) (26.039 mm)
S3D86E-7, 1.0234 - 1.0236 in. 1.0222 in.
Pin outside diameter
4D88E-7, (25.995 - 26.000 mm) (25.965 mm)
S4D86E-7 0.0000 - 0.0006 in. 0.0029 in. See Inspection
Oil clearance of pistons,
(0.000 - 0.014 mm) (0.074 mm)
Piston pin piston rings and
1.1811 - 1.1815 in. 1.1826 in. wrist pin on
Hole inside diameter
(30.000 - 30.009 mm) (30.039 mm) page 6-54.
4D98E-7, 1.1809 - 1.1811 in. 1.1797 in.
Pin outside diameter
S4D98E-7 (29.995 - 30.000 mm) (29.965 mm)
0.0000 - 0.0006 in. 0.0029 in.
Oil clearance
(0.000 - 0.014 mm) (0.074 mm)

6-10 86E-7 – 98E-7 Series

 Crankshaft and Piston Specifications ENGINE
Piston Ring
Reference
Model Inspection item Standard Limit
page
0.0813 - 0.0819 in.
Ring groove width –
(2.065 - 2.080 mm)
0.0776 - 0.0783 in. 0.0768 in.
Ring width
(1.970 - 1.990 mm) (1.950 mm)
Top ring
0.0030 - 0.0043 in.
Side clearance –
(0.075 - 0.110 mm)
0.0079 - 0.0157 in. 0.0193 in.
End gap
(0.200 - 0.400 mm) (0.490 mm)
0.0801 - 0.0807 in. 0.0846 in.
Ring groove width
(2.035 - 2.050 mm) (2.150 mm)
0.0768 - 0.0776 in. 0.0760 in. See Inspection
Ring width of pistons,
S3D86E-7, (1.950 - 1.970 mm) (1.930 mm)
Second ring piston rings and
S4D86E-7 0.0018 - 0.0039 in. 0.0079 in.
Side gap wrist pin on
(0.045 - 0.100 mm) (0.200 mm) page 6-54.
0.0118 - 0.0197 in. 0.0232 in.
End gap
(0.30 - 0.50 mm) (0.590 mm)
0.1581 - 0.1587 in. 0.1626 in.
Ring groove width
(4.015 - 4.030 mm) (4.130 mm)
0.1563 - 0.1571 in. 0.01555 in.
Ring width
(3.970 - 3.990 mm) (3.950 mm)
Oil ring
0.0010 - 0.0024 in. 0.0071 in.
Side clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0079 - 0.0157 in. 0.0193 in.
End gap
(0.200 - 0.400 mm) (0.490 mm)

86E-7 – 98E-7 Series 6-11

ENGINE Crankshaft and Piston Specifications

(Piston ring cont.)

Reference
Model Inspection item Standard Limit
page
0.0807 - 0.0817 in.
Ring groove width –
(2.050 - 2.075 mm)
0.0776 - 0.0783 in. 0.0768 in.
Ring width
(1.970 - 1.990 mm) (1.950 mm)
Top ring
0.0028 - 0.0041 in.
Side clearance –
(0.070 - 0.105 mm)
0.0079 - 0.0157 in. 0.0193 in.
End gap
(0.200 - 0.400 mm) (0.490 mm)
0.0797 - 0.0803 in. 0.0843 in.
Ring groove width
(2.025 - 2.040 mm) (2.140 mm)
0.0776 - 0.0783 in. 0.0768 in. See Inspection
Ring width of pistons,
3D88E-7, (1.970 - 1.990 mm) (1.950 mm)
Second ring piston rings and
4D88E-7 0.0014 - 0.0028 in. 0.0075 in.
Side clearance wrist pin on
(0.035 - 0.070 mm) (0.190 mm) page 6-54.
0.0079 - 0.0157 in. 0.0193 in.
End gap
(0.20 - 0.40 mm) (0.490 mm)
0.1581 - 0.1587 in. 0.1626 in.
Ring groove width
(4.015 - 4.030 mm) (4.130 mm)
0.1563 - 0.1571 in. 0.1555 in.
Ring width
(3.970 - 3.990 mm) (3.950 mm)
Oil ring
0.0010 - 0.0024 in. 0.0071 in.
Side clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0079 - 0.0157 in. 0.0193 in.
End gap
(0.200 - 0.400 mm) (0.490 mm)

6-12 86E-7 – 98E-7 Series

 Crankshaft and Piston Specifications ENGINE
(Piston ring cont.)

Reference
Model Inspection item Standard Limit
page
0.0803 - 0.0811 in.
Ring groove width –
(2.040 - 2.060 mm)
0.0764 - 0.0772 in. 0.0756 in.
Ring width
(1.940 - 1.960 mm) (1.920 mm)
Top ring
0.0031 - 0.0047 in.
Side clearance –
(0.080 - 0.120 mm)
0.0098 - 0.0177 in. 0.0213 in.
End gap
(0.250 - 0.450 mm) (0.540 mm)
0.0819 - 0.0825 in. 0.0864 in.
Ring groove width
(2.080 - 2.095 mm) (2.195 mm)
0.0776 - 0.0783 in. 0.0768 in. See Inspection
Ring width of pistons,
4D98E-7, (1.970 - 1.990 mm) (1.950 mm)
Second ring piston rings and
S4D98E-7 0.0035 - 0.0049 in. 0.0096 in.
Side clearance wrist pin on
(0.090 - 0.125 mm) (0.245 mm) page 6-54.
0.0177 - 0.0256 in. 0.0287 in.
End gap
(0.450 - 0.650 mm) (0.730 mm)
0.1187 - 0.1193 in. 0.1232 in.
Ring groove width
(3.015 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring width
(2.970 - 2.990 mm) (2.950 mm)
Oil ring
0.0010 - 0.0024 in. 0.0071 in.
Side clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0098 - 0.0177 in. 0.0217 in.
End gap
(0.250 - 0.450 mm) (0.550 mm)

86E-7 – 98E-7 Series 6-13

ENGINE Crankshaft and Piston Specifications

Connecting Rod
■ Connecting rod small end
Reference
Model Inspection item Standard Limit
page
1.0234 - 1.0251 in. 1.0263 in.
Wrist pin bushing inside diameter
3D88E-7, (26.025 - 26.038 mm) (26.068 mm)
S3D86E-7, 1.0234 - 1.0236 in. 1.0223 in.
Wrist pin outside diameter
4D88E-7, (25.995 - 26.000 mm) (25.967 mm)
S4D86E-7 0.0010 - 0.0017 in. 0.0040 in.
Oil clearance See Inspection
(0.025 - 0.043 mm) (0.101 mm) of connecting
1.1821 - 1.1826 in. 1.1838 in. rod on
Wrist pin bushing inside diameter page 6-56.
(30.025 - 30.038 mm) (30.068 mm)
4D98E-7, 1.1809 - 1.1811 in. 1.1797 in.
Wrist pin outside diameter
S4D98E-7 (29.995 - 30.000 mm) (29.965 mm)
0.0010 - 0.0017 in. 0.0040 in.
Oil clearance
(0.025 - 0.043 mm) (0.101 mm)

■ Connecting rod big end

Reference
Inspection item Standard Limit
page
See Inspection
0.0079 - 0.0157 in. of connecting
Side clearance - all models –
(0.20 - 0.40 mm) rod on
page 6-56.

Note: See Special Torque Chart on page 6-17 for other specifications.

6-14 86E-7 – 98E-7 Series

 Crankshaft and Piston Specifications ENGINE
Tappet
Reference
Model Inspection item Standard Limit
page
0.4724 - 0.4734 in. 0.4742 in.
Tappet bore (block) inside diameter
3D88E-7, (12.000 - 12.025 mm) (12.045 mm)
S3D86E-7, 0.4715 - 0.4720 in. 0.4707 in.
Tappet stem outside diameter
4D88E-7, (11.975 - 11.990 mm) (11.955 mm)
S4D86E-7 0.0004 - 0.0020 in. 0.0035 in.
Oil clearance See Inspection
(0.010 - 0.050 mm) (0.090 mm)
of tappets on
0.4724 - 0.4731 in. 0.4739 in. page 6-57.
Tappet bore (block) inside diameter
(12.000 - 12.018 mm) (12.038 mm)
4D98E-7, 0.4715 - 0.4720 in. 0.4707 in.
Tappet stem outside diameter
S4D98E-7 (11.975 - 11.990 mm) (11.955 mm)
0.0004 - 0.0017 in. 0.0033 in.
Oil clearance
(0.010 - 0.043 mm) (0.083 mm)

86E-7 – 98E-7 Series 6-15

ENGINE Cylinder Block Specifications

CYLINDER BLOCK SPECIFICATIONS

Cylinder Block
Reference
Inspection item Model Standard Limit
page
3.4646 - 3.4657 in. 3.4724 in.
3D88E-7 - 4D88E-7
(88.000 - 88.030 mm) (88.200 mm)
3.3858 - 3.3870 in. 3.3937 in.
Cylinder inside diameter S3D86E-7, S4D86E-7 See Inspection
(86.000 - 86.030 mm) (86.200 mm)
of cylinder block
3.8583 - 3.8594 in. 3.8634 in.
4D98E-7, S4D98E-7 on page 6-54.
(98.000 - 98.030 mm) (98.130 mm)
Roundness 0.0004 in. (0.01 mm) 0.0012 in.
Cylinder bore
Taper or less (0.03 mm)

6-16 86E-7 – 98E-7 Series

 Special Torque Chart ENGINE

SPECIAL TORQUE CHART

Torque for Bolts and Nuts
Lubricating oil
Thread diameter application
Component Model Torque
and pitch (Thread portion and
seat surface)
68 - 72 ft·lb
3D88E-7, S3D86E-7,
M10 × 1.25 mm (92.0 - 98.0 N·m;
4D88E-7, S4D86E-7
9.4 - 10.0 kgf·m)
Cylinder head bolt Applied
76 - 83 ft·lb
4D98E-7, S4D98E-7 M11 × 1.25 mm (103.1 - 112.9 N·m;
10.5 - 11.5 kgf·m)
33 - 36 ft·lb
3D88E-7, S3D86E-7,
M9 × 1.0 mm (44.1 - 49.0 N·m;
4D88E-7, S4D86E-7
4.5 - 5.0 kgf·m)
Connecting rod bolt Applied
40 - 43 ft·lb
4D98E-7, S4D98E-7 M10 × 1.0 mm (53.9 - 58.8 N·m;
5.5 - 6.0 kgf·m)
61 - 65 ft·lb
3D88E-7, S3D86E-7,
M10 × 1.25 mm (83.3 - 88.2 N·m;
4D88E-7, S4D86E-7
8.5 - 9.0 kgf·m)
Flywheel bolt Applied
137 - 152 ft·lb
4D98E-7, S4D98E-7 M14 × 1.5 mm (186.2 - 205.8 N·m;
19 - 21 kgf·m)
70.8 - 73.8 ft·lb
3D88E-7, S3D86E-7,
M12 × 1.5 mm (96.0 - 100 N·m;
4D88E-7, S4D86E-7
9.8 - 10.2 kgf·m)
Main bearing cap bolt Applied
80 - 87 ft·lb
4D98E-7, S4D98E-7 M11 × 1.25 mm (108.1 - 117.9 N·m;
11.0 - 12.0 kgf·m)
Cast metal (FC300)
62 - 69 ft·lb
(83.3 - 93.1 N·m;
3D88E-7, S3D86E-7, 8.5 - 9.5 kgf·m)
M14 × 1.5 mm
4D88E-7, S4D86E-7 Steel metal (S45C)
Crankshaft pulley bolt 83 - 91 ft·lb Applied
(112.7 - 122.7 N·m;
11.5 - 12.5 kgf·m)
80 - 94 ft·lb
4D98E-7, S4D98E-7 M14 × 1.5 mm (107.9 - 127.5 N·m;
11.0 - 13.0 kgf·m)

86E-7 – 98E-7 Series 6-17

ENGINE Special Torque Chart

(Torque for bolts and nuts cont.)

Lubricating oil
Thread diameter application
Component Model Torque
and pitch (Thread portion and
seat surface)
18 - 21 ft·lb
Fuel injector retainer
All models M8 × 1.25 mm (24.4 - 28.4 N·m; Not applied
bolt
2.5 - 2.9 kgf·m)
55 - 63 ft·lb
Supply pump drive gear
All models M18 × 1.5 mm (75 - 85 N·m; Not applied
nut
7.7 - 8.7 kgf·m)
21.7 - 25.3 ft·lb
M12 × 1.5 mm
(29.4 - 34.3 N·m;
Common rai
3.0 - 3.5 kgf·m)
19.5 - 25.3 ft·lb
High pressure fuel line M12 × 1.5 mm
All models (26.5 - 34.3 N·m; Not applied
nut Injector
2.7 - 3.5 kgf·m)
21.7 - 25.3 ft·lb
M16 × 1.0 mm
(29.4 - 34.3 N·m;
Supply pump
3.0 - 3.5 kgf·m)
4.4 - 7.4 ft·lb
Crank rotation sensor All models M6 × 1.0 mm (6.0 - 10.0 N·m; Not applied
0.6 - 1.0 kgf·m)
5.5 - 6.3 ft·lb
Cam speed sensor All models M6 × 1.0 mm (7.5 - 8.5 N·m; Not applied
0.75 - 0.85 kgf·m)
3D88E-7,
14.0 - 18.2 ft·lb
S3D86E-7,
M8 × 1.25 mm (18.9 - 24.7 N·m; Not applied
4D88E-7,
1.9 - 2.5 kgf·m)
Pipe, EGR valve S4D86E-7
43.3 - 47.0 ft·lb
4D98E-7,
M10 × 1.5 mm (58.7 - 63.7 N·m; Not applied
S4D98E-7
6.0 - 6.5 kgf·m)
3D88E-7, 4.1 - 6.2 ft·lb
4D88E-7, (5.6 - 8.4 N·m;
New air temperature 4D98E-7 0.57 - 0.86 kgf·m)
M6 × 1.0 mm Not applied
sensor S3D86E-7, 2.2 - 3.0 ft·lb
S4D86E-7, (3.0 - 4.0 N·m;
S4D98E-7 0.31 - 0.41 kgf·m)
8.1 - 12.5 ft·lb
Intake temperature
All models M14 × 1.5 mm (11.0 - 17.0 N·m; Not applied
sensor
1.1 - 1.7 kgf·m)

6-18 86E-7 – 98E-7 Series

 Special Torque Chart ENGINE
(Torque for bolts and nuts cont.)

Lubricating oil
Thread diameter application
Component Model Torque
and pitch (Thread portion and
seat surface)
18.4 - 29.5 ft·lb
Exhaust temperature
All models M12 × 1.25 mm (25.0 - 40.0 N·m; Not applied
sensor
2.5 - 4.1 kgf·m)
33.2 - 40.6 ft·lb
KDPF inlet temperature
All models M14 × 1.5 mm (45.0 - 55.0 N·m; Not applied
sensor
4.6 - 5.6 kgf·m)
33.2 - 40.6 ft·lb
KDPF inside
All models M12 × 1.25 mm (45.0 - 55.0 N·m; Not applied
temperature sensor
4.6 - 5.6 kgf·m)
4.1 - 6.2 ft·lb
KDPF differential
All models M6 × 1.0 mm (5.6 - 8.4 N·m; Not applied
pressure sensor
0.57 - 0.86 kgf·m)
Bolt, KDPF differential 18.1 - 25.3 ft·lb
Burning prevention
pressure sensor pipe All models M12 × 1.25 mm (24.5 - 34.3 N·m;
medicine
joint 2.5 - 3.5 kgf·m)
8.9 - 11.0 ft·lb
4D98E-7,
Nut, valve cover M8 × 1.5 mm (12.0 - 15.0 N·m; Not applied
S4D98E-7
1.2 - 1.5 kgf·m)
11.1 - 14.8 ft·lb
Glow plug All models M10 × 1.25 mm (15 - 20 N·m; Not applied
1.53 - 2.04 kgf·m)
0.7 - 1.1 ft·lb
Glow connector nut All models M4 × 0.7 mm (1 - 1.5 N·m; Not applied
0.1 - 0.15 kgf·m)
S3D86E-7, 9.4 - 12.3 ft·lb
Piston cooling nozzle
S4D86E-7, M8 × 1.25 mm (12.7 - 16.7 N·m; Not applied
banjo bolt
S4D98E-7 1.3 - 1.7 kgf·m)

Note: See Tightening Torques for Standard Bolts and Nuts on page 4-37 for standard hardware torque
values.

86E-7 – 98E-7 Series 6-19

ENGINE Special Service Tools

SPECIAL SERVICE TOOLS

No. Tool name Applicable model and tool size Illustration

Model L1 L2 d1 d2 L2
Valve guide tool d2
0.787 in. 2.953 in. 0.295 in. 0.433 in.
1 (for removing All models L1
(20 mm) (75 mm) (7.5 mm) (11 mm)
valve guide)
Locally manufactured
d1
010932-00X

Model L1 L2 d1 d2 L2
Valve guide tool 0.591 in. 2.559 in. 0.551 in. 0.787 in.
2 (for installing All models L1
(15 mm) (65 mm) (14 mm) (20 mm)
valve guide)
Locally manufactured
d1
d2 001421-00X

Connecting rod Model L1 L2 d1 d2

bushing 3D88E-7, L2
replacer (for S3D86E-7, 0.787 in. 3.937 in. 1.024 in. 1.142 in. d2
3 removal/ 4D88E-7, (20 mm) (100 mm) (26 mm) (29 mm) L1
installation of S4D86E-7
connecting rod 4D98E-7, 0.787 in. 3.937 in. 1.181 in. 1.299 in.
bushing) d1
S4D98E-7 (20 mm) (100 mm) (30 mm) (33 mm) 010933-00X

Locally manufactured

Valve spring
compressor
4 (for removal/ Part No. YM129100-92630
installation of
valve spring) 010931-00X

Model d1 d2 d3 L1 L2 L3 L2
0.638 0.866 0.531 0.740 2.559 L1
0.157
in. in. in. in. in.
All models in.
(16.2 (22 (13.5 (18.8 (65
(4 mm) d1
mm) mm) mm) mm) mm)
d2 001421-00X
Stem seal Locally manufactured
installer
5 (for installing
valve stem
seal)

L2
d3 L3
d1 L1
d2

001422-00X

6-20 86E-7 – 98E-7 Series

 Special Service Tools ENGINE

No. Tool name Applicable model and tool size Illustration

Filter wrench
(for removal/
6 Available locally
installation of
engine oil filter)

002829-01X

Model L1 L2 d1 d2
Camshaft 3D88E-7, L2
bushing tool S3D86E-7, 0.709 in. 2.756 in. 1.772 in. 1.890 in.
7 (for extracting 4D88E-7, (18 mm) (70 mm) (45 mm) (48 mm) L1
camshaft S4D86E-7
bushing) 4D98E-7, 0.709 in. 2.756 in. 1.968 in. 2.087 in. d1
d2
S4D98E-7 (18 mm) (70 mm) (50 mm) (53 mm) 001421-00X

Locally manufactured

Model Part No. Cylinder bore

3D88E-7,
Flex-hone
S3D86E-7, 3.268 - 3.740 in.
(for preparation YM129400-92430
8 4D88E-7, (83 - 95 mm)
of cylinder
S4D86E-7
walls)
4D98E-7, 3.504 - 3.976 in.
YM129400-92440
S4D98E-7 (89 - 101 mm) 010930-00X

Piston ring
Part No. YM95550-002476
compressor
9 The piston insertion tool is applicable for
(for installing
2.362 - 4.921 in. (60 - 125 mm) diameter pistons
piston)

007236-00X

Piston ring
expander
10 (for removal/ Available locally
installation of
piston ring)
001411-00X

86E-7 – 98E-7 Series 6-21

ENGINE Special Service Tools

No. Tool name Applicable model and tool size Illustration

25

0.2 A
46
26 20
Crankshaft
18 M14×1.5
pulley installing Locally manufactured Knurl knob A

1
11
tool (4D98E-7, S4D98E-7 series)

ø39 -0.05
-0.15
(for taper pilot)

ø35
C
1
039124-00X00

C
5

0.
0.

0.

5
C

5
16 17
ø0.03 A 039125-00E00

25

30 26
6 20
Knurl knob
Crankshaft m0.3 25 17
pulley installing
Locally manufactured 1.6
12 tool A
(4D98E-7, S4D98E-7 series) M14×1.5
(for straight
ø42 +0.075
+0.063

ø29.7

pilot)
C
1

0.2 A
5 R1

C
1
C

0.
0.

5
C

ø0.03 A 039126-00E00

6.3

0.05 A 0.1 A
(16) 36
20
5 M14 x 1.5
0.
C
0.

16 C
5

Pulley installing 3D88E-7, S3D86E-7, 1

13 C
ø 35.4 -0.05
-0.15

tool 4D88E-7, S4D86E-7

ø6

1
C

A
3
52
Knurling

6-22 86E-7 – 98E-7 Series

 Special Service Tools ENGINE

No. Tool name Applicable model and tool size Illustration

13 -0.1
0
16mmx18/1inch
(Whitworth screw thread)

13
25 ø13

82
Compression
18
(5)

gauge adapter
14
(YM129A00-
(141)

92950)
(1)

(ø16)
68

ø17

R0
.2
17

0
ø7.2 -0.1
043931-00E00

86E-7 – 98E-7 Series 6-23

ENGINE Measuring Instruments

MEASURING INSTRUMENTS
No. Instrument name Application Illustration

1 Dial Indicator Locally available Measure shaft bend and end play.

001429-00X

Measurements of narrow or deep portions that

2 Test indicator Locally available
cannot be measured by dial gauge.
001430-00X

3 Magnetic stand Locally available For holding the dial gauge when measuring.

001431-00X

For measuring the outside diameters of

4 Micrometer Locally available
crankshaft, pistons, piston pins, etc.
001432-00X

For measuring the inside diameters of cylinder

5 Cylinder bore gauge Locally available
liners, bearing bores, etc.
001433-00X

For measuring outside diameters, depth,

6 Calipers Locally available
thickness and width.
001434-00X

7 Depth micrometer Locally available For measuring of valve recession.

001435-00X

For measuring valve spring inclination and

8 Square Locally available
straightness of parts.

001436-00X

6-24 86E-7 – 98E-7 Series

 Measuring Instruments ENGINE

No. Instrument name Application Illustration

9 V-block Locally available For measuring shaft bend.

001437-00X

For tightening nuts and bolts to the specified

10 Torque wrench Locally available
torque.
001438-00X

For measuring piston ring gaps, piston ring

11 Feeler gauge Locally available
clearance, and valve adjustment clearance.

001426-00X

86E-7 – 98E-7 Series 6-25

ENGINE Cylinder Head

CYLINDER HEAD
Cylinder Head Components

3
1
2 4
5
6 7

34

8
32
33
29
9 10
27 11
37 28
30 12
31
35 17 13
36 14
18
15
19

20 16

21

22

23

26
24
25
061221-00X00

Figure 6-1

6-26 86E-7 – 98E-7 Series

 Cylinder Head ENGINE
1 – Valve cover nut
2 – Valve cover nut O-ring
3 – Crankcase breather cover
4 – Diaphragm spring
5 – Diaphragm plate
6 – Crankcase breather diaphragm
(non-turbocharged engines only)
7 – Oil fill cap
8 – Valve cover gasket
9 – Rocker arm shaft spring
10 – Valve adjusting screw lock nut
11 – Valve adjusting screw
12 – Rocker arm
13 – Rocker arm shaft
14 – Rocker arm shaft aligning stud
15 – Support bolt
16 – Rocker arm shaft support
17 – Valve cap
18 – Valve keepers
19 – Spring retainer
20 – Valve spring
21 – Valve stem seal
22 – Valve guide
23 – Cylinder head
24 – Intake valve
25 – Exhaust valve
26 – Cylinder head gasket
27 – Fuel injector retainer
28 – Washer
29 – Fuel injector retainer bolt
30 – Fuel injector nozzle protector
31 – Fuel injector nozzle seat
32 – Push rod
33 – Crankcase breather components
34 – Valve cover
35 – Glow plug
36 – Connector
37 – Wire harness

86E-7 – 98E-7 Series 6-27

ENGINE Cylinder Head

Disassembly of Cylinder Head

6 5 4
Prepare a clean, flat working surface on a 7
workbench large enough to accommodate the
cylinder head assembly. Discard all gaskets,
O-rings and seals. Use new gaskets, O-rings and
seals on reassembly of the cylinder head.
1. Drain the coolant from the engine into a suitable
container. See Operation & Maintenance
Manual.

NOTICE
Identify all parts and their location using an
appropriate method. It is important that all parts 3
are returned to the same position during the 1 2
reassembly process. 043929-00X00

Figure 6-3
2. Disconnect the electrical wire from the glow 6. Disconnect the electrical wire from the diesel
plug, injector, intake throttle, EGR valve and particulate filter if mounted.
sensors (Figure 6-2, (1)).
7. Remove the diesel particulate filter (KDPF)
from the engine (discard the all gasket).
8. Remove the exhaust manifold bolts
(Figure 6-3, (4)) and nuts (Figure 6-3, (5)).
Remove the exhaust manifold (Figure 6-3, (6))
and the exhaust manifold gasket
1 (Figure 6-3, (7)).
9. Remove the coolant pump. See Disassembly of
Engine Coolant Pump on page 8-7.
10. Remove the high-pressure lines and fuel
043927-00X00
injectors from the cylinder head. See Removal
of Injector on page 7-11.
Figure 6-2
3. Disconnect the fuel pipes from the fuel filter, if
the fuel filter is mounted on the intake manifold.
4. Remove the intake throttle, EGR valve and fuel
filter on the intake manifold if required (discard
the all gasket).
5. Remove the intake manifold bolts
(Figure 6-3, (1)). Remove the intake manifold
(Figure 6-3, (2)). Discard the intake manifold
gasket (Figure 6-3, (3)).

6-28 86E-7 – 98E-7 Series

 Cylinder Head ENGINE
■ Removing the glow plugs ■ Removal of valve cover
1. Remove the glow plug harness 1. Disconnect the electrical wire from sensors on
(Figure 6-4, (2), (3)) from each glow plug the valve cover.
(Figure 6-4, (1)). 2. Remove the valve cover nuts (Figure 6-5, (1)).
2. Remove the glow plug from the cylinder head. 3. Remove the O-ring (Figure 6-5, (2)) on each
valve cover nut.
3
1
2
1
2

K0001920

061222-00X00
Figure 6-5
Figure 6-4
4. Remove the valve cover (Figure 6-5, (3)) and
Note: Removing the cylinder head from the the valve cover gasket (Figure 6-5, (4)).
engine requires that the glow plugs be
removed in advance.
Failure to remove the glow plugs in
advance could result in damages to the
glow plugs because their tips are
protruding from the cylinder head
combustion chamber surface.

86E-7 – 98E-7 Series 6-29

ENGINE Cylinder Head

■ Removal of rocker arm assembly ■ Disassembly of rocker arm assembly

1. Remove the bolts (Figure 6-6, (1)) that retain 1. Remove the rocker arm shaft alignment stud
the rocker arm shaft supports. (Figure 6-7, (4)) from support (Figure 6-7, (5)).
2. Remove the rocker arm shaft assembly from Note: The rocker arm shaft fits tightly in the
the cylinder head. rocker arm supports. Clamp the support
Note: Identify the push rods so they can be in a padded vise. Twist and pull out on
reinstalled in their original locations. the rocker arm shaft to remove. Reverse
this process when you reinstall the
3. Remove the push rods and identify for rocker arm shaft into the supports.
installation.
2. Slide the rocker arm shaft (Figure 6-7, (3)) out
of the rocker arm supports (Figure 6-7, (5)),
springs (Figure 6-7, (1)), and rocker arms
(Figure 6-7, (2)).
Note: Mark the rocker arms so they can be
reinstalled with the original matching
valve and pushrod.
1

7
6
1
2

3
4

5
K0001950

Figure 6-6
K0001951

Figure 6-7
3. Remove the valve adjusting screw
(Figure 6-7, (6)) and the lock nut
(Figure 6-7, (7)) from the rocker arms.

6-30 86E-7 – 98E-7 Series

 Cylinder Head ENGINE
■ Removal of cylinder head 2. Remove the cylinder head bolts
1. Loosen the cylinder head bolts following the (Figure 6-9, (1)).
sequence shown in (Figure 6-8). 3. Lift the cylinder head away from the cylinder
block. Discard the cylinder head gasket
2 (Figure 6-9, (2)). Position the cylinder head on
the work bench to prevent damage to the
8 14 5
2 12 9 3 combustion surface.
1
4 10 11 1
6 13 7

2
7 16 14 6
1 9 18 12 4

1
3 11 17 10 2
5 13 15 8

K0001864

1 – Cooling fan end

2 – Camshaft side
Figure 6-8

K0001690

Figure 6-9

86E-7 – 98E-7 Series 6-31

ENGINE Cylinder Head

■ Removal of intake/exhaust valves 8. Turn the cylinder head so the exhaust port side
1. Place the cylinder head on the work bench with faces down. Remove the intake and exhaust
the combustion side down. valves (Figure 6-11, (6)) from the cylinder
head.
2. Remove the valve cap (Figure 6-11, (1)) and
keep with the valve it was installed on. 9. Remove the valve stem seals
(Figure 6-11, (5)).
3. Using the valve spring compressor tool,
compress one of the valve springs ■ Removal of valve guides
(Figure 6-10).
Note: Removal of the valve guides should be
postponed until inspection and
measurement procedures have been
performed. See Inspection of valve guides
on page 6-34.
1. If the valve guides were not within
specifications, use a drift pin and hammer to
K0000191
drive the valve guides (Figure 6-12, (1)) out of
the cylinder head.
Figure 6-10
4. Remove the valve keepers (Figure 6-11, (2)).
5. Slowly release the tension on the valve spring.
1
6. Remove the spring retainer (Figure 6-11, (3))
and valve spring (Figure 6-11, (4)).

1
2
3
4
K001689X
5
Figure 6-12

K0001684

Figure 6-11
7. Repeat the procedure with all remaining valves.
Note: If the valves are to be reused, identify
them so they can be installed in their
original location.

6-32 86E-7 – 98E-7 Series

 Cylinder Head ENGINE
Cleaning of Cylinder Head ■ Inspection of push rods
Components Push rod bend
Determine if the bend of the push rods are within
WARNING the specified limit.
Fume/Burn Hazard!
1. Place the push rods on a flat inspection block or
• Always read and layout bed.
follow safety related
precautions found on 2. Roll the push rods until a gap can be observed
containers of between a portion of the push rod and the
hazardous substances surface of the block or layout bed.
like parts cleaners, 3. Use a feeler gauge to measure the gap
primers, sealants and (Figure 6-13). See Push Rod on page 6-6 for
sealant removers. the service limit.
• Failure to comply could result in death or
serious injury.

Thoroughly clean all components using a non-

metallic brush and an appropriate solvent. Each
part must be free of carbon, metal filings and other
debris.

Inspection of Cylinder Head

Components K0000204

Visually inspect the parts. Replace any parts that Figure 6-13
are obviously discolored, heavily pitted or
otherwise damaged. Discard any parts that do not
meet its specified limit.

NOTICE
Any part which is found defective as a result of
inspection or any part whose measured value does
not satisfy the standard or limit must be replaced.

NOTICE
Any part determined to not meet the service
standard or limit before the next service, as
determined from the state of current rate of wear,
should be replaced even though the part currently
meets the service standard limit.

86E-7 – 98E-7 Series 6-33

ENGINE Cylinder Head

■ Inspection of rocker arm assembly ■ Inspection of valve guides

Rocker arm shaft hole diameter Visually inspect the valve guides for distortions,
scoring or other damage.
Use a test indicator and micrometer to determine if
the inside diameter of all the rocker arm support Note: Measure the valve guides while they are
brackets and the rocker arms (Figure 6-14) are installed in the cylinder head.
within the specified limits. See Rocker Arm and
Use a telescoping gauge and micrometer to
Shaft on page 6-6 for the service limit.
measure the inside diameter at each end of the
Inspect the contact areas (Figure 6-14, (1)) for valve guide. Measure in three places and 90° apart
excessive wear or damage. (Figure 6-16). See Intake/Exhaust Valve and
Guide on page 6-5 for the service limit. Replace
valve guides if not within specification.

K0001869

1 Figure 6-16
1

■ Inspection of cylinder head

K0001916 Cylinder head distortion
Place the cylinder head flat and inverted
Figure 6-14
(combustion side up) on the bench. Use a straight
Rocker arm shaft outside diameter edge and a feeler gauge to measure cylinder head
distortion (Figure 6-17). Measure diagonally and
Use a micrometer to measure the rocker arm shaft
along each side. See Cylinder Head on page 6-4
diameter. Measure at each rocker arm location in
for the service limit.
two directions 90° apart (Figure 6-15). See Rocker
Arm and Shaft on page 6-6 for the service limit.

K0000192

Figure 6-17
If distortion exceeds the service limit, resurface or
replace the cylinder head. Remove only enough
material to make the cylinder head flat, but do not
K0001952
remove more than 0.008 in. (0.20 mm).
Figure 6-15

6-34 86E-7 – 98E-7 Series

 Cylinder Head ENGINE
■ Inspection of intake and exhaust valves Valve recession
Visually inspect the intake and exhaust valves. Note: The valve guides must be installed to
Replace any valves that are obviously discolored, perform this check.
heavily pitted or otherwise damaged. Insert the valves into their original locations and
Valve stem diameter press them down until they are fully seated. Use a
depth micrometer (Figure 6-20) to measure the
Use a micrometer to measure the valve stem
difference between the cylinder head gasket
diameter. Measure the valve stem near the
surface and the combustion surface of each
combustion end and near the opposite end
exhaust and intake valve (Figure 6-21). See
(Figure 6-18, (1)). See Intake/Exhaust Valve and
Cylinder Head on page 6-4 for the service limit.
Guide on page 6-5 for the service limit.

K0000197

Figure 6-18

Valve stem bend

Place the valve stem on a flat inspection block or K0000193
layout bed. Roll the valve until a gap can be
observed between a portion of the valve stem and Figure 6-20
the surface of the block or bed. Use a feeler gauge
to measure the gap (Figure 6-19). See
Intake/Exhaust Valve and Guide on page 6-5 for
the service limit.

K0001755

K0000199 Figure 6-21

Figure 6-19

86E-7 – 98E-7 Series 6-35

ENGINE Cylinder Head

Valve face and valve seat

Always check the clearance between the valve and 1
valve guide before grinding or lapping the valve 150° 40°
seats. See Intake/Exhaust Valve and Guide on
page 6-5 for the service limit. If the clearance 3
exceeds the limit, replace the valve and/or valve 2
guide to bring the clearance within the limit.
Roughness or burrs will cause poor seating of a K0001862

valve. Visually inspect the seating surfaces of each

valve and valve seat to determine if lapping or Figure 6-23
grinding is needed. The valve seat diameter can be adjusted by top-
Visually inspect all valve faces and valve seats for grinding with a 150° stone to make the seat
pitting, distortion, cracking, or evidence of diameter smaller, and bottom-grinding using a 40°
overheating. Usually the valves and the valve seats stone to make the seat diameter larger. Once the
can be lapped or ground to return them to seat location has been corrected, grind and lap the
serviceable condition. Severely worn or damaged seat angle (Figure 6-23, (1)) to specification. See
components will require replacement. Cylinder Head on page 6-4 for specifications.

Coat the valve seat with a thin coat of bluing Grind the valve face and/or valve seat only enough
compound. Install the valve and rotate it to to return them to serviceable condition. Grinding is
distribute bluing onto the valve face. The contact needed if the valve and the valve seat do not
pattern should be approximately centered on the contact correctly. Check the recession after
valve face (Figure 6-22, (1)) and even in width. grinding.
If the valve or seat require grinding, lap the valve
after grinding. Lap the valve face to the valve seat
using a mixture of valve lapping compound and
engine oil.
Be sure to thoroughly wash all parts to remove all
grinding powder or compound.

■ Inspection of valve springs

Inspect the valve springs. If damage or corrosion is
1 seen, or if measurements exceed the specified
limits, replace the springs.

Fractures
K0001691B
Check for fractures on the inside and outside
Figure 6-22 portions of the springs. If the valve spring is
fractured, replace the valve spring.
Also visually inspect the valve seat for even
contact. Corrosion
Check for corrosion of the spring material caused
Light cutting can be performed by the use of a by oxidation.
hand-operated cutter (Figure 6-23, (3)).

6-36 86E-7 – 98E-7 Series

 Cylinder Head ENGINE
Squareness Reassembly of Cylinder Head
Use a flat surface and a square to check each Use new gaskets, O-rings and seals for the
spring for squareness (Figure 6-24). See Valve reassembly of the cylinder head.
Spring on page 6-6 for the service limit.
NOTICE
Liberally oil all components during reassembly to
prevent premature wear or damage.

■ Reassembly of valve guides

1. The valve guides are installed into the cylinder
K0000201
head with an extremely tight press fit. Before
installing the valve guides, place the valve guides
Figure 6-24 in a freezer for at least twenty minutes This will
cause the valve guides to contract, making it
Free length easier to install the valve guides into place.
Use a caliper to measure the length of the spring 2. Immediately after removing the valve guides
(Figure 6-25). See Valve Spring on page 6-6 for from the freezer, insert the valve guides
the service limit. (Figure 6-26, (1)) in their proper positions.

1
2
3
1

4
0

5
9

6
8
7

K0000200
K001689X

Figure 6-25 Figure 6-26

3. Finish installing the valve guides
(Figure 6-27, (1)) into the cylinder head to the
proper height (Figure 6-27, (3)) using the valve
guide installation tool (Figure 6-27, (2)). See
Valve Guide Projection specification starting on
page 6-5.

1
K0001756A

Figure 6-27

86E-7 – 98E-7 Series 6-37

ENGINE Cylinder Head

■ Reassembly of intake and exhaust valves

NOTICE
Always install new valve stem seals.
The exhaust valve stem seals are different than the 2
1
intake valve stem seals and can be identified by
either the paint marks on the outside of the seals or
by the color of the seal spring (Figure 6-28, (4)).
Ensure they are installed in the correct locations.

K0001874

Marking
Engine model Figure 6-29
Intake Exhaust
White (Paint on 3. Place the cylinder head assembly on its
All models None
outside of seal) exhaust port side.
4. Place all the valves (Figure 6-30, (6)) in their
1. Oil the lip of the valve stem seal
proper location in the cylinder head.
(Figure 6-28, (2)). Using the valve stem seal
installation tool (Figure 6-28, (1)), install a new
valve stem seal on each of the valve guides 1
(Figure 6-28, (3)). 2
3
4
5
1

3
6

K0001873B K0001684

Figure 6-28 Figure 6-30

2. Measure the distance (Figure 6-29, (1)) from 5. Place the cylinder head on the workbench with
the cylinder head to valve stem seal to ensure the combustion side down to install the valve
proper clearance (Figure 6-29, (2)) between springs. Install the valve spring
the guide and the seal. See Valve Stem Seal (Figure 6-30, (4)) and the spring retainer
Projection specification on page 6-6. (Figure 6-30, (5)).
6. Using the valve spring compressor tool,
compress the valve spring.
7. Insert the valve keepers (Figure 6-30, (2)) and
slowly release the tension on the valve spring.
Install the valve cap (Figure 6-30, (1)). Repeat
the steps on all the remaining valves.

6-38 86E-7 – 98E-7 Series

 Cylinder Head ENGINE
■ Reassembly of cylinder head 3. Lightly oil the threads of the cylinder head bolts
1. Carefully clean both the combustion surface of (Figure 6-31, (1)). Tighten the bolts to the
the cylinder head and the top surface of the specified torque in two steps as shown in the
cylinder block. Then place a new cylinder head chart below. Tighten in the sequence shown in
gasket (Figure 6-31, (2)) on the cylinder block. (Figure 6-32). See Special Torque Chart on
page 6-17 for specification.
2. Position the cylinder head on the cylinder head
gasket. First step 1/2 of final torque
Second step Final torque

1 4. Insert the push rods in their respective positions.

2
7 1 10
13 3 6 12

1
11 5 4 14
9 2 8

2
12 3 5 13
18 10 1 7 15

1
16 8 2 9 17
14 6 4 11

2 K0001875

1 – Fan end
2 – Camshaft side
Figure 6-32

■ Reassembly of rocker arm reassembly

NOTICE
Ensure the lubrication holes (Figure 6-33, (1)) in
K0001690
the rocker arm shaft are oriented correctly with
Figure 6-31 respect to the rocker arms (Figure 6-33, (2)).

1 2

1 045200-00X00

Figure 6-33

86E-7 – 98E-7 Series 6-39

ENGINE Cylinder Head

1. Lubricate the rocker arm shaft. Slide the rocker 7. Adjust the valve clearance. See Measuring and
arm supports (Figure 6-34, (5)), springs Adjusting Valve Clearance on page 6-42.
(Figure 6-34, (1)) and rocker arms
(Figure 6-34, (2)) onto the shaft. ■ Reassembly of the valve cover
Note: 1. Lightly grease a new valve cover gasket
(Figure 6-35, (4)). Place the gasket in the
• The rocker arm shaft fits tightly in the rocker groove of the valve cover (Figure 6-35, (3)).
arm supports. Clamp the support in a padded
vise. Twist and push on the rocker arm shaft to 2. Place the valve cover on the cylinder head.
reinstall. 3. Be sure new O-rings (Figure 6-35, (2)) are
• To properly align the rocker arm shaft with the installed on the valve cover nuts. Reinstall and
rocker arm shaft supports, first reinstall a tighten the valve cover nuts (Figure 6-35, (1)).
rocker arm support (Figure 6-34, (5)) having a 4. Reinstall the exhaust manifold using a new
hole for the shaft alignment stud gasket. Tighten the bolts to the specified
(Figure 6-34, (4)). Align the hole in the rocker torque.
arm shaft and the hole in the rocker arm
support. Reinstall the alignment stud. 1
2
7
6
1
2

3
3
4

4
5
K0001920

K0001951
Figure 6-35
5. Reinstall the intake manifold using a new
Figure 6-34
gasket. Tighten the bolts to the specified
Note: Figure 6-34 shows components for one torque.
cylinder. Components for all remaining 6. Install each glow plug (Figure 6-36, (1)), and
cylinders are assembled in the same tighten it with the specified torque. Install each
order. electrical harness (Figure 6-36, (2), (3)), and
2. Place the rocker arm shaft assembly onto the tighten it with the specified torque.
cylinder head.
3. If removed, reinstall the valve adjusting screws
(Figure 6-34, (6)) and the lock the nuts
(Figure 6-34, (7)).
4. Align the push rods with their respective rocker
arms.
5. Reinstall and tighten the rocker arm shaft
retaining bolts (M10 × 65) to the specified
torque.
6. Tighten the rocker arm shaft alignment studs.

6-40 86E-7 – 98E-7 Series

 Cylinder Head ENGINE

1
2

061222-00X00

Figure 6-36
7. Reinstall the fuel injectors. See Reassembly of
injector on page 7-12.
8. Reinstall the high pressure and the return fuel
injection lines. See Removal of Common Rail
on page 7-9
9. Reinstall the engine coolant pump. See
Reassembly of Engine Coolant Pump on
page 8-9.

CAUTION
For high-pressure pipe, use a new one. If you
reuse it, the displacement of the working face
may occur, causing the fuel leaks.

10. Reinstall the coolant hoses on the cold start

device on the fuel injection pump.
11. Reinstall the alternator. See Installation of
Alternator on page 12-14.

86E-7 – 98E-7 Series 6-41

ENGINE Measuring and Adjusting Valve Clearance

MEASURING AND ADJUSTING • If there is no valve clearance, and the cylinder is

at TDC of the compression stroke, extreme wear,
VALVE CLEARANCE or damage to the cylinder head or valves may be
Measure and adjust while the engine is cold. possible.

Note: • If adjusting each cylinder individually, the cylinder

to be adjusted first does not have to be the No. 1
• The No. 1 piston position is on the flywheel end of cylinder. Select and adjust the cylinder where the
the engine, opposite the radiator. The firing order piston is nearest to the top dead center after
is 1-3-2 for 3-cylinder engines and 1-3-4-2 for 4- turning. Make adjustment for the remaining
cylinder engines. cylinders in the order of firing by turning the
• 3-cylinder engines fire every 240° of crankshaft crankshaft each time.
rotation. • To decrease the number of rotations required to
• 4-cylinder engines fire every 180° of crankshaft check all cylinders, other cylinders can also be
rotation. checked as indicated in the chart below.

• Valve clearance of both the intake and exhaust Example: On a 3-cylinder engine, with the No. 1
valves can be checked with the piston for that piston at TDC on the compression stroke (both
cylinder at top dead center (TDC) of the valves closed), the valves indicated on the top line
compression stroke. When a piston is at TDC of of the chart can be adjusted without rotating the
the compression stroke, both rocker arms will be crankshaft. To adjust the remaining two valves,
loose and the cylinder TDC mark on the flywheel rotate the crankshaft until the No. 1 piston is at TDC
will be visible in the timing port of the flywheel on the exhaust stroke (exhaust valve only open).
housing.

■ 3-cylinder engines
Cylinder No. 1 2 3
Valve Intake Exhaust Intake Exhaust Intake Exhaust
No. 1 cylinder at TDC compression ● ● ● ●
No. 1 cylinder at TDC exhaust ● ●

■ 4-cylinder engines
Cylinder No. 1 2 3 4
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
No. 1 cylinder at TDC compression ● ● ● ●
No. 4 cylinder at TDC compression ● ● ● ●

6-42 86E-7 – 98E-7 Series

 Measuring and Adjusting Valve Clearance ENGINE
1. Remove the valve cover. See Removal of valve
cover on page 6-29.
2
Note: If adjusting each cylinder individually, the
cylinder to be adjusted first does not
have to be the No. 1 cylinder. Select and
adjust the cylinder where the piston is
nearest to the top dead center after
turning, and make adjustment for other
cylinders in the order of firing by turning
the crankshaft.
2. Rotate the crankshaft clockwise as seen from
the coolant pump end, to bring No. 1 piston to 1
TDC on the compression stroke while watching
Figure 6-38
the rocker arm motion and timing grid on the
flywheel. (Position where both the intake and 6. Insert a feeler gauge of the correct thickness
exhaust valves are closed.) (Figure 6-39, (1)) (see Adjustment
3. Insert a feeler gauge (Figure 6-37, (1)) Specifications on page 6-4) between the rocker
between the rocker arm and valve cap, and arm and valve cap. Turn the valve adjustment
record the measured valve clearance. (Use the screw to adjust the valve clearance so there is
data for estimating the wear.) a slight “drag” on the feeler gauge when sliding
it between the rocker arm and the valve cap.
Hold the adjusting screw while tightening the
1
valve adjusting screw lock nut
(Figure 6-38, (1)). Recheck the clearance.
Note: There is a tendency for the clearance to
decrease slightly when the lock nut is
tightened. It is suggested that you make
the initial clearance adjustment slightly
on the “loose” side before tightening the
lock nut.

K0001782A

Figure 6-37
4. If adjustment is required, proceed to the next
step.
5. Loosen the valve adjusting screw lock nut
Figure 6-39
(Figure 6-38, (1)) and valve adjusting screw
(Figure 6-38, (2)) on the rocker arm and check 7. Apply oil to the contact surface between the
the valve for inclination of the valve cap, adjusting screw and push rod.
entrance of dirt, or wear. 8. Rotate the crankshaft. Measure and adjust the
valves on the next cylinder. Continue until all
the valves have been measured and adjusted.

86E-7 – 98E-7 Series 6-43

ENGINE Crankshaft and Camshaft Components

CRANKSHAFT AND CAMSHAFT COMPONENTS

41 1

42 3
4
2

40 6
39
38 7
36
37 35 8
9
10 5
34
33

30 13
18 12
32
19 11
31

17
16
20 15
21 14
22
23
24
29

25
26

27

28

043952-00X00

Figure 6-40

6-44 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE
1 – Cylinder block Disassembly of Engine
2 – Camshaft bushing
3 – Gear case Prepare a clean, flat working surface on a
4 – Gear case cover workbench large enough to accommodate the
5 – Front crankshaft seal engine components. Discard all used gaskets,
6 – Tappets O-rings and seals. Use new gaskets, O-rings and
7 – Camshaft seals on reassembly of engine.
8 – Camshaft gear key
9 – Camshaft end plate
10 – Camshaft gear
NOTICE
11 – Idler gear shaft (A) Identify all parts and their location using an
12 – Idler gear (A) appropriate method. It is important that all parts are
13 – Idler gear bushing (A) returned to the same position during the
14 – Idler gear plate (B) reassembly process.
15 – Idler gear shaft (B)
16 – Idler gear (B)
17 – Idler gear bushing (B) If the engine will be completely disassembled, the
18 – Oil pickup gasket
following preliminary steps should be performed:
19 – Oil pickup
20 – Crankshaft 1. Disconnect the battery cables at the battery.
21 – Ball Always disconnect the negative (-) cable first.
22 – Crankshaft gear key
23 – Crankshaft gear 2. Remove the throttle cable, electrical
24 – Crankshaft pulley connections, intake and exhaust system
25 – Main bearing inserts connections, and fuel supply lines from the
26 – Main bearing cap engine.
27 – Oil pan spacer 3. Remove the alternator. See Removal of
28 – Oil pan
Alternator on page 12-10.
29 – Thrust bearings
30 – Flywheel 4. Drain the engine coolant from the radiator and
31 – Connecting rod cap cylinder block. See Operation & Maintenance
32 – Connecting rod bearing inserts Manual. Remove the cooling system
33 – Connecting rod components from the engine.
34 – Wrist pin bushing
35 – Circlip
5. Remove the engine from the machine. Mount
36 – Wrist pin the engine to a suitable engine repair stand
37 – Piston having adequate weight capacity.
38 – Oil ring
39 – Second compression ring NOTICE
40 – Top compression ring Be sure to secure the engine solidly to prevent
41 – Crankshaft rear seal housing
injury or damage to parts due to the engine falling
42 – Crankshaft rear seal
during work on the engine.

6. Clean the engine by washing with solvent, air or

steam cleaning. Carefully operate so as to
prevent any foreign matter or fluids from
entering the engine or any fuel system or
electrical components remaining on the engine.
7. Drain the engine oil into a suitable container.
Remove the oil filter.
8. Remove the cylinder head. See Cylinder Head
on page 6-26.
9. Remove fuel supply pump if necessary.
See Removal of Supply Pump on page 7-13 if
necessary.

86E-7 – 98E-7 Series 6-45

ENGINE Crankshaft and Camshaft Components

10. Remove the starter motor. See Removal of Check the backlash between each pair of mating
Starter Motor on page 11-8. gears (Figure 6-42). If not within specification,
replace both mating gears. See Timing Gear
Disassembly of Camshaft and Timing Backlash on page 6-8 for service limits.
Components Note: Do not allow the gear being checked to
Discard all gaskets, O-rings and seals. Use new move axially as excess end play could cause
gaskets, O-rings and seals on reassembly of the a false reading.
camshaft and timing components.
1 2 3 4
■ Removal of timing gear case cover
1. Remove the bolt and washer retaining the
crankshaft pulley.

NOTICE
Use care not to damage the threads in the end of
the crankshaft when removing the crankshaft
pulley.
5
6
2. Remove the crankshaft pulley using a gear 7 043953-00X00

puller.
1 – Supply pump gear
3. Remove the bolts that retain the gear case 2 – Idler gear (B)
cover to the cylinder block and oil pan. 3 – Idler gear (A)
4. Remove the gear case cover (Figure 6-41, (1)). 4 – Camshaft gear
5 – Crankshaft gear
6 – Lubricating oil pump gear
7 – Direction of rotation
Figure 6-42

K0001641A

Figure 6-41

■ Checking timing gear backlash

Prior to removing the timing gears, measure the
gear backlash and determine the gear wear.

6-46 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE
■ Measuring idler gear-to-crankshaft gear ■ Removal of timing gears
backlash 1. Remove the bolts from the idler gear shaft
1. Install a dial indicator as shown in Figure 6-43. (Figure 6-44, (1)). Remove the idler gear shaft,
idler gear (Figure 6-44, (2)) and bushing
(Figure 6-44, (3)).

2
3
1

6
043954-00X00
5
4
3
1
043957-01X00

1 – Idler gear shaft

2 – Idler gear (B)
3 – Idler gear bushing
4 – Idler gear (A)
5 – Plate, idle shaft
6 – Packing
Backside engagement
clearance (backlash) Figure 6-44
007778-00E

2. Do not remove the crankshaft gear unless it is

Figure 6-43 damaged and requires replacement. If the gear
2. Rotate the idler gear back and forth to check must be removed, remove it using a gear puller.
the idler gear-to-crankshaft gear backlash. The 3. Removal of the camshaft gear requires the
total indicator reading is the backlash. Record camshaft be removed and placed in a press. Do
the measurement. not remove the camshaft gear unless it or the
camshaft is damaged and requires
■ Measuring idler gear-to-camshaft gear replacement. See Removal of camshaft on
backlash page 6-48.
1. Drive a small wooden wedge between the 4. Remove the supply pump drive gear using a
crankshaft gear and idler gear to prevent the gear puller.
idler gear from rotating.
2. Install the dial indicator to read the camshaft
gear backlash. Rotate the camshaft drive gear
against the idler gear to measure the backlash.
Record the measurement.
3. Check the idler gear-to-fuel injection pump
drive gear backlash in the same manner as the
camshaft drive gear. Record the measurement.

043958-00X00

Figure 6-45

86E-7 – 98E-7 Series 6-47

ENGINE Crankshaft and Camshaft Components

■ Removal of oil pan ■ Removal of camshaft

1. Invert the engine (oil pan up) on the engine 1. Before removing the camshaft, check the
stand. camshaft end play.
2. Remove the oil pan (Figure 6-46, (1)). • Method A: Install a dial indicator
(Figure 6-48, (1)) on the cylinder block. Move
the camshaft (Figure 6-48, (2)) back and forth
to measure the end play. Record the
measurement. See Camshaft on page 6-7 for
the service limit.

2
043959-00X00
K0001695A

Figure 6-48
Figure 6-46
• Method B: Use a feeler gauge to measure the
3. Remove the oil pickup tube (Figure 6-47, (1)) clearance between the thrust plate
and O-ring (Figure 6-47, (2)). (Figure 6-49, (1)) and front camshaft bearing
(Figure 6-49, (2)). See Thrust Bearing on
page 6-10 for the service limit.

2
1

K0001710B

Figure 6-49
K0001696A

Figure 6-47

6-48 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE
2. Remove the two bolts (Figure 6-50, (3)) ■ Removal of gear case or front plate
retaining the camshaft thrust plate Note: The camshaft must be removed before the
(Figure 6-50, (1)). gear case can be removed. See Inspection
of camshaft on page 6-58.
1. Remove the oil pump.
Note: It is not necessary to remove the fuel supply
2 5
pump from the gear case to remove the gear
case. If the fuel supply pump does not need
1 to be repaired, leaving it mounted to the
timing gear case will eliminate the need to
3 4 re-time it during assembly. See Removal of
Supply Pump on page 7-13.
2. Remove the bolts (Figure 6-51, (4)).
K0001966 3. Remove the gear case (Figure 6-51, (1)) from
the cylinder block. Thoroughly clean all old
Figure 6-50 sealant from the mating surfaces.
3. Rotate the engine in the engine stand so that 4. Inspect and measure the camshaft bushing.
gravity causes the tappets (Figure 6-50, (5)) to See Camshaft on page 6-7 for the service limit.
drop away from the camshaft lobes. If damaged or worn beyond service limits,
Note: Rotate the camshaft at least two turns to remove the camshaft bushing
“bump” any sticking tappets away from (Figure 6-51, (3)).
the camshaft. 5. 4D98E-7, S4D98E-7: Remove two O-rings
(Figure 6-51, (2)).
4. Slowly pull the camshaft (Figure 6-50, (2))
assembly out of the engine being careful not to
damage the front camshaft bushing.
Note:
• If the engine is not installed on an engine repair
fixture, stand the engine upright on the flywheel
3 1
end mounting flange. Rotate the camshaft at
least two turns to bump the tappets out of the
way to prevent the tappets from interfering with
the removal of the camshaft.
4
• The tappets are “mushroom” shaped and must
be removed from inside the engine crankcase.
5. Remove the tappets. Mark the tappets so they 2
can be reinstalled in the same location. K0001737B

6. Remove the camshaft drive gear

(Figure 6-50, (4)) only if the gear or camshaft Figure 6-51
require replacement. Use a knife-edge puller
and a press to remove the gear. The gear is a
shrink-fit and will need to be heated to 356 -
392 °F (180 - 200 °C) to remove.

86E-7 – 98E-7 Series 6-49

ENGINE Crankshaft and Camshaft Components

6. 3D88E-7 - S4D86E-7: Remove the O-ring 1. Using a feeler gauge, measure the connecting
(Figure 6-52, (2)) and dowels rod side clearance as shown (Figure 6-53).
(Figure 6-52, (4)). See Connecting Rod on page 6-14 for the
standard limit. If the measurement is out of
specification, replace the crankshaft,
connecting rod, or both.
3
4
1

2
4
043961-00X02

Figure 6-52

Disassembly of Crankshaft and

Piston Components
K0000219

■ Removal of pistons
Figure 6-53
NOTICE 2. Measure bearing oil clearance prior to removing
Keep the piston pin parts, piston assemblies, and the pistons and connecting rods to determine
connecting rod assemblies together to be returned extent of wear. Record the measurements.
to the same position during the reassembly
process. Label the parts using an appropriate NOTICE
method. Mark the connecting rod caps and connecting
rods so the caps and connecting rods stay
NOTICE together.
Engines with high operating hours may have a
ridge near the top of the cylinders that will catch the
1- Remove the bearing cap. Do not remove the
piston rings and make it impossible to remove the
bearing inserts at this time.
pistons. Use a suitable ridge reamer to remove
ridges and carbon prior to removing the pistons. 2- Wipe oil from the bearing insert and
crankshaft journal surfaces.
3- Place a piece of PLASTIGAGE®
Note: Pistons can fall from cylinder block if the (Figure 6-54, (1)) along the full width of the
engine is inverted. Rotate the engine so the bearing insert.
connecting rods are horizontal before
removing the connecting rod caps.

6-50 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE
3. Use a wooden dowel against the connecting
rod and tap the piston/connecting rod assembly
1 out of the cylinder.
4. Mark the cylinder number on the piston and
connecting rod.
5. Remove the bearing inserts (Figure 6-56, (2)).
6. Remove the compression rings
K0001898 (Figure 6-56, (3)) from the piston using a piston
ring expander.
Figure 6-54 7. Remove the oil ring (Figure 6-56, (4)) from the
piston using a piston ring expander.
NOTICE
Do not rotate the crankshaft when using 3
PLASTIGAGE. A false reading may result.
4
5
4- Reinstall bearing cap and tighten to
specification. See Special Torque Chart on 9 6
page 6-17. 5
5- Remove bearing cap.
6- Compare the width of the flattened 8
PLASTIGAGE to the graduation marks on 7
the package (Figure 6-55, (1)). The mark
that most closely matches the width of the 2
flattened PLASTIGAGE will indicate the
bearing oil clearance. 1

K0001960

1 Figure 6-56
8. Remove the circlips (Figure 6-56, (5)) from the
wrist pin.

K0001899
9. Remove the wrist pin (Figure 6-56, (6)) and
connecting rod (Figure 6-56, (8)) from the
Figure 6-55 piston (Figure 6-56, (9)).
10. Repeat the steps until all pistons are removed
7- Repeat with remaining connecting rods.
and dissembled.
NOTICE
Do not allow the connecting rod to contact the
crankshaft journal during piston removal.
Damage to the bearing journal may result.

86E-7 – 98E-7 Series 6-51

ENGINE Crankshaft and Camshaft Components

■ Removal of crankshaft • Method B: Use a feeler gauge to measure the

1. Remove the flywheel (Figure 6-57, (1)) from clearance (Figure 6-59, (3)) between the
the crankshaft. thrust bearing (Figure 6-59, (1)) and
crankshaft (Figure 6-59, (2)). Record the
2. Remove the bolts from the rear oil seal measurement. See Thrust Bearing on
assembly (Figure 6-57, (2-3)). Remove the page 6-10 for the service limit.
assembly from the engine.

2
3
1
1 2

3
K0001962

K0001707A Figure 6-59

Figure 6-57 4. Remove the main bearing caps

(Figure 6-60, (3)). Be sure to note the markings
3. Before removing the main bearing caps, on the main bearing caps, or mark them
measure the crankshaft end play. Use either of yourself, so they can be reinstalled in the same
the following two methods. order as they were removed. Do not remove the
• Method A: Install a dial gauge bearing inserts at this time.
(Figure 6-58, (1)) on the cylinder block. Move Note: The “arrows” on the main bearing caps
the crankshaft (Figure 6-58, (2)) in and out to point to the flywheel end of the engine.
measure the end play. Record the
measurement.

1
1
2 K0001961

Figure 6-58
3
K0001752A

Figure 6-60

6-52 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE
5. Measure bearing oil clearance prior to removing 6. Remove the crankshaft from the engine.
the crankshaft to determine extent of wear. 7. Remove the bearing inserts (Figure 6-60, (1))
Record the measurements. and thrust bearings (Figure 6-60, (2)).
1- Wipe oil from the bearing insert and Note: Do not remove the crankshaft gear
crankshaft journal surfaces. unless the gear or crankshaft are
2- Place a piece of PLASTIGAGE damaged and require replacement.
(Figure 6-61, (1)) along the full width of
8. If necessary, remove the crankshaft gear
each bearing insert.
(Figure 6-63, (1)), parallel pin
(Figure 6-63, (2)) and key (Figure 6-63, (3)). If
using a gear puller, be careful not to damage
1
the threads in the end of the crankshaft.

2
3

K0001898
1

Figure 6-61
K0001731A

NOTICE Figure 6-63

Do not rotate the crankshaft when using
PLASTIGAGE. A false reading may result. Inspection of Crankshaft and
Camshaft Components
3- Reinstall bearing caps and tighten to WARNING
specification. See Special Torque Chart on
page 6-17. Fume/Burn Hazard!
4- Remove bearing caps. • Always read and
follow safety related
5- Compare the width of the flattened
precautions found on
PLASTIGAGE to the graduation marks on
containers of
the package (Figure 6-62, (1)). The mark
hazardous substances
that most closely matches the width of the
like parts cleaners,
flattened PLASTIGAGE will indicate the
primers, sealants and
bearing oil clearance.
sealant removers.
• Failure to comply could result in death or
serious injury.

1 Thoroughly clean all components using a brush

and appropriate solvent. Each part must be free of
carbon, gasket material, metal filings and other
debris.
K0001899

Figure 6-62

86E-7 – 98E-7 Series 6-53

ENGINE Crankshaft and Camshaft Components

■ Replacement of crankshaft oil seals ■ Measure crankshaft bearing oil clearance

1. Remove the seal (Figure 6-64, (2)) from the Oil clearance should be checked during
cover (Figure 6-64, (1)). disassembly to determine the extent of wear, and
2. Apply a continuous bead of ThreeBond Liquid during assembly to ensure long engine life. The
Gasket No. 1207F, Part No. YM977770-1207F same procedure is done for both connecting rods
to the outside diameter of a new oil seal and main bearings.
(Figure 6-64, (2)), and install in the gear case
■ Inspection of cylinder block
cover. Apply lithium grease to the lip of the seal.
1. Ensure that oil passages are clear and
unobstructed.
2. Check for discoloration or evidence of cracks. If
a fracture is suspected, use the color check
method or the Magnaflux method to determine
if the cylinder block is fractured.
3. Inspect cylinders for roundness, taper, or
1 evidence of scoring. Collect and record the
measurements. Consider honing, reboring or
replacing the cylinder block if the
measurements are not within specification.
2
• Take measurements at three places
(Figure 6-66) (a, b, c), and in two directions (d
K0001735A and e) in each cylinder.
Figure 6-64
a 20 mm
3. Remove the rear oil seal (Figure 6-65, (3)) from (0.75 in.)
d
the seal housing (Figure 6-65, (2)). e
b
4. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1207F, Part No. YM977770-1207F
to the outside diameter of a new oil seal c
(Figure 6-65, (2)), and install in the housing. 20 mm
Apply lithium grease to the lip of the seal. (0.75 in.) K0000230B

Figure 6-66

■ Inspection of pistons, piston rings and

2 wrist pin
3 Note:
1 • On an engine with low hours, the pistons, piston
rings may be reused if they are found to be within
specifications. The pistons and piston rings must
be reinstalled in the same cylinders from which
they were originally removed.
• On an engine with high hours, the pistons rings
K0001707A
should be replaced and the cylinder honed (See
Honing and Boring on page 6-60) or replaced.
Figure 6-65 The piston should be replaced as necessary.

6-54 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE
1. Clean piston ring grooves using a piston ring
groove cleaning tool. Follow manufacturer’s
instructions for correct operation.
2. Wash the pistons in an appropriate solvent
using a soft brush.
3. Visually inspect each piston for cracks. Pay
particular attention to the ring lands between
the piston ring grooves.
4. Measure the diameter of the piston skirt at 90°
to the wrist pin bore as shown (Figure 6-67). K0000237

Measurements must be taken at a specified

Figure 6-68
distance (Figure 6-67, (1)) from the bottom of
the piston, based on engine model. Record the 7. Measure the outside diameter of the wrist pin in
measurements. See Piston on page 6-10 for three places and at 90° (Figure 6-69). See
specifications. Piston on page 6-10 for specifications. Record
the measurements.

1 K0001889

Figure 6-69
K0000235

8. Using a micrometer, measure the thickness of

Figure 6-67 each piston ring. See Piston on page 6-10 for
specifications. Record the measurements.
5. Subtract the piston measurement from the
greatest measurement acquired during cylinder Note:
inspection (see Inspection of cylinder block on
• On an engine with low hours, the pistons,
page 6-54) to obtain piston-to-cylinder
piston rings and cylinders may be reused if
clearance. Record the measurements. See
they are found to be within specifications.
Piston on page 6-10 for specifications.
• On an engine with high hours, the pistons rings
6. Measure the diameter of the wrist pin bore on
should be replaced and the cylinder honed
both sides of the piston (Figure 6-68). See
(see Honing and Boring on page 6-60) or
Piston on page 6-10 for specifications. Record
replaced. The piston should be replaced as
the measurements.
necessary.
9. Place each compression piston ring in the
groove as shown (Figure 6-70). Use a feeler
gauge to measure the clearance between the
piston ring and the piston ring land. Record the
measurements. See Piston Ring on page 6-11
for specifications. Replace the piston if not
within specification.

86E-7 – 98E-7 Series 6-55

ENGINE Crankshaft and Camshaft Components

Note: Always check the piston ring end gap when

installing new piston rings. See Piston Ring
on page 6-11 for specifications. Use a piston
ring end gap filing tool to adjust the piston
ring end gap on new piston rings.
11. Repeat the above steps for each cylinder and
piston assembly.

■ Inspection of connecting rod

1. Measure the wrist pin bushing bore using a
bore gauge (Figure 6-72, (1)). Replace the
K0001892 bushing if not within specifications. If the
bushing has been removed, measure the inside
Figure 6-70 diameter of the connecting rod small end
(Figure 6-72, (2)). See Connecting Rod on
10. To measure piston ring end gap, insert each
page 6-14 for specifications.
compression piston ring (Figure 6-71, (1)), one
at a time, into the cylinder. Use a piston with the
piston rings removed to slide the ring into the
cylinder bore until it is approximately 1.18 in.
(30 mm) (Figure 6-71, (2)) from the bottom of
the bore. Remove the piston. Measure the end
gap (Figure 6-71, (3)) of each piston ring.
Record the measurements. See Piston Ring on
page 6-11 for specifications.

K0001724A

Figure 6-72
2. Place the connecting rod bearing inserts into
the connecting rod and connecting rod cap.
Install the rod cap and tighten the bolts to the
1 specified torque.
2 3. Measure the inside diameter. See Crankshaft
on page 6-9 for specifications.

3 K0001964

Figure 6-71

6-56 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE
■ Inspection of tappets ■ Inspection of crankshaft
1. Inspect the tappet contact surfaces for 1. Place the crankshaft end journals
abnormal wear (Figure 6-73, (1)). Normal wear (Figure 6-75, (4)) on V-blocks.
will be even as shown in (Figure 6-73, (2)). 2. Place a dial indicator (Figure 6-75, (3)) on a
Slight surface defects can be corrected using center main bearing surface.
an oilstone.

2
1

3
1 2 K0001725

Figure 6-73
2. Measure the outside diameter of the tappet
stem (Figure 6-74, (1)). See Tappet on
page 6-15 for the service limit.
4 4 K0000232A

Figure 6-75
3. Rotate the crankshaft and observe runout. See
Crankshaft on page 6-9 for specifications.
4. Use the color check method or Magnaflux® to
inspect the crankshaft for cracks. Replace the
crankshaft if evidence of fractures are found.
1
K0001726A
5. Measure the outside diameter of each crankpin
(Figure 6-76, (2)) and main bearing journal
Figure 6-74 (Figure 6-76, (1)). See Crankshaft on page 6-9
3. Measure the tappet bores in the cylinder block. for specifications. Take measurements at
See Tappet on page 6-15 for the service limit. several places around each bearing surface. If
not within specification, grind the journals and
install undersize bearings, or replace the
crankshaft.

86E-7 – 98E-7 Series 6-57

ENGINE Crankshaft and Camshaft Components

■ Inspection of camshaft
1. Use V-blocks and a dial indicator to check
camshaft bend (Figure 6-77). Place the
indicator on the center bearing journal.

K0001711

R Figure 6-77

R 2. Rotate the camshaft and observe the runout.

See Camshaft on page 6-7 for specifications.
3. Measure the height of each lobe
(Figure 6-78, (1)). See Camshaft on page 6-7
1 for specifications.
2 K0001733A

Figure 6-76
1

K0001712A

Figure 6-78
4. Measure the diameter of the gear end
(Figure 6-79, (1)), intermediate
(Figure 6-79, (2)), and flywheel end
(Figure 6-79, (3)) bearing journals. See
Camshaft on page 6-7 for specifications.

2
1

K0001713A

Figure 6-79

6-58 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE
■ Inspection of camshaft bushing and ■ Inspection of flywheel
bores 1. Check for crack and wear on the flywheel
1. Measure the I.D. of the front bushing and the friction surface, and replace it if there is
remaining bores in the cylinder block. See damage.
Camshaft on page 6-7 for specifications. 2. Check the ring gear tooth surface and replace
2. If the camshaft bushing is not within the ring gear if there is damage or excessive
specification, replace it using the appropriate wear.
service tool. If the remaining bores are not • Removal of ring gear
within specification, the cylinder block will Bring a rod into contact with the ring gear, and
require replacement as there are no bearing remove the gear while evenly hitting the
inserts used. circumference with a hammer.
■ Inspection of idler gear and shaft
1. Measure the outside diameter
(Figure 6-80, (1)) of the idler gear shaft
(Figure 6-80, (2)). See Idler Gear Shaft and
Bushing on page 6-8 for specifications.
2. Measure the inside diameter (Figure 6-80, (3))
of the idler gear bushing (Figure 6-80, (4)). See
Idler Gear Shaft and Bushing on page 6-8 for
specifications.

061228-00X00
4
Figure 6-81
• Evenly heat a new ring gear with a gas burner
1 3
(approximately 200 °C (392 °F)), quickly install
the ring gear with the chamfered side of the
2 tooth surface facing the block side. Completely
and closely contact the ring gear and the
flywheel.
K0001714A

Figure 6-80

061229-00X00

Figure 6-82

86E-7 – 98E-7 Series 6-59

ENGINE Crankshaft and Camshaft Components

Honing and Boring

1
Pistons must move freely in the cylinders while
maintaining adequate compression and oil sealing.
If the cylinder walls are scuffed, scored,
out-of-round, or tapered beyond specifications,
rebore and hone to restore cylinders to usable
condition. Slight imperfections can be corrected by
honing alone.
1. Boring - Significant cylinder damage may be
corrected by boring the cylinder to an oversize
dimension. Refer to the appropriate Parts Book
K0000248A
for available oversize pistons and piston rings.
• Boring a cylinder should always be done in a Figure 6-83
properly equipped machine shop.
• Use a 50:50 mixture of diesel fuel and engine
• A bored cylinder should always be finished with oil as a honing fluid.
a hone to properly prepare the cylinder surface
so the new piston rings will seat properly. • Use a 300-grit hone at 300 - 1200 min-1 (rpm)
(Figure 6-84).
• After the cylinder has been bored and honed,
install the appropriate oversize pistons and
1
piston rings.
2. Honing - Minor cylinder imperfections may be 2
corrected by using a rigid cylinder hone
(Figure 6-84, (1)). Be sure not to exceed the
maximum cylinder bore specification.
Deglazing - A used cylinder that did not require
boring or honing, should always be deglazed
with a ball hone (Figure 6-84, (2)) before K0000249B

installing new piston rings. This will properly

prepare the cylinder surface to allow new piston Figure 6-84
rings to seat properly.
NOTICE
Note: When honing a cylinder, with either a ridged
hone or a ball hone (Figure 6-83, (1)), move Solvents will not adequately remove honing
the rotating hone up and down in the cylinder residue, resulting in premature piston and ring
bore to accomplish a 30° to 40° crosshatch wear. Always wash cylinders using hot, soapy
pattern (Figure 6-83). This will provide the water.
ideal surface for the proper seating of new
piston rings.
• When honing is completed, wash the cylinder
block with hot water and soap. The cylinder
NOTICE wall is adequately cleaned when a white rag
Do not allow the honing tool to operate in one wiped in cylinder comes out clean. Use
position for any length of time. Damage to the brushes to clean all passages and crevices.
cylinder wall will occur. Keep the tool in constant Rinse with hot water and dry with compressed
up-and-down motion. air. Apply clean engine oil to all steel surfaces
to prevent rusting.

6-60 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE
Reassembly of Crankshaft and NOTICE
Piston Components
The piston and connecting rod must be
Note: assembled together in the correct orientation.
• Proceed slowly. Make no forced assemblies The orientation of the piston and connecting rod
unless a pressing operation is called for. All parts are different depending on engine model.
must be perfectly clean and lightly lubricated
when assembled.
Piston to connecting rod orientation - by model
• Use new gaskets, seals and O-rings during Orient the piston identification mark stamped on top of
assembly. the piston on the same side as the rod and cap match
marks stamped on the connecting rod.
• Liberally apply clean engine oil to all internal parts
during assembly. Note: The actual appearance of the match
• All fasteners should be tightened to a given marks on the piston and connecting rod
torque. If a special torque is not provided in the may vary, but they will always be in the
Special Torque Chart on page 6-17, tighten to same locations.
standard torque specifications. See Tightening
Torques for Standard Bolts and Nuts on
page 4-37. 1
■ Reassembly of pistons
1. Select the parts needed to reassemble the

ML↓844V
piston and connecting rod for one cylinder.
2. If removed, install a new wrist pin bushing
(Figure 6-85, (7)) using a press and the
appropriate service tool. Be sure to align the oil
holes.

3
K0002091

4
5
2
9 6
5
E106 R

8
7
K0002090

2
3
1

80 80
K0001960

K0002089
Figure 6-85
1 – Piston identification mark
3. Reinstall one circlip (Figure 6-85, (5)) into the
2 – Embossed mark on connecting rod
piston. Ensure the circlip is securely seated in 3 – Rod and cap match marks
the groove.
Figure 6-86

86E-7 – 98E-7 Series 6-61

ENGINE Crankshaft and Camshaft Components

Piston assembly - all this series engine

models 3
When correctly assembled, the piston 4
identification mark (Figure 6-87, (2)) stamped
5
into the top of the piston will be on the same side
of the connecting rod as the match marks 9 6
(Figure 6-87, (4)) stamped into the connecting 5
rod and connecting rod cap.
When installed in the cylinder, the piston 8
identification mark (Figure 6-87, (2)) stamped 7
on the top of the piston must face the fuel
injection pump side (Figure 6-87, (1)) of the
engine and the embossed mark on the 2
connecting rod (Figure 6-87, (3)) must face the 1
flywheel end (Figure 6-87, (5)) of the engine.

K0001960
6 1
Figure 6-88
Note:
2
5 • If installing new piston rings the end gap must
be checked and adjusted as necessary. See
Inspection of pistons, piston rings and wrist pin
3 on page 6-54 for specifications. Use a piston
ring end gap filing tool to adjust the piston ring
4 end gap on new piston rings.
• Reinstall the top and second piston rings with
K0001967 the stamped “makers mark” (Figure 6-89, (1))
facing the top of the piston. The “makers mark”
1 – Fuel injection pump side of engine
may vary in appearance but will always be
2 – Piston identification mark
located on the top surface of the piston ring
3 – Embossed mark on connecting rod
4 – Rod and cap match marks adjacent to the piston ring gap. The oil ring and
5 – Flywheel end of engine oil ring expander can be installed either side
6 – Camshaft side of engine up.
Figure 6-87
1
4. Lubricate and reinstall the wrist pin
(Figure 6-88, (6)) through the piston and
connecting rod.
K0000225A
5. Reinstall the second circlip (Figure 6-88, (5))
and ensure it is securely seated in the groove. Figure 6-89

6-62 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE

NOTICE 1
Always use a piston ring installation tool
(expander) when installing piston rings. Never
attempt to install piston rings by hand.
2

6. Reinstall the oil ring expander 3

(Figure 6-90, (4)). Reinstall the oil ring
(Figure 6-90, (3)) with the end gap at 180° from
the expander end gap.
7. Reinstall the second compression ring
(Figure 6-90, (2)). This ring is identified by its
dark color and tapered face profile.
8. Reinstall the top compression ring
(Figure 6-90, (1)). This ring is identified by its K0001968

silver color and barrel-shaped face profile.

1 – Top compression ring end gap
NOTICE 2 – Second compression ring end gap
3 – Oil ring end gap
The oil ring expander (Figure 6-90, (4)) end gap
must be located 180° from the oil ring Figure 6-91
(Figure 6-90, (3)) end gap.
■ Installation of crankshaft
1. If removed, reinstall the keys and timing gear
on the crankshaft.

1 2. Reinstall new bearing inserts (Figure 6-92, (1))

and thrust bearing (Figure 6-92, (2)) in the
cylinder block and main bearing caps. Apply a
liberal coat of clean engine oil to the bearings
2 and crankshaft journals.
3. Place the crankshaft into the engine.
3
NOTICE
The main bearing caps are numbered and have
4 arrows for proper positioning. The No. 1 cap is at
K0001722B
the flywheel end. The arrows point toward the
flywheel end of the engine.
Figure 6-90
9. Stagger the piston ring end gaps at 120°
intervals (Figure 6-91, (1, 2, 3)). Do not 4. Reinstall the main bearing caps
position the top piston ring end gap in line with (Figure 6-92, (3)).
the wrist pin.

86E-7 – 98E-7 Series 6-63

ENGINE Crankshaft and Camshaft Components

5. Apply a light coat of clean engine oil to the ■ Installation of pistons

bearing cap bolts and tighten the bolts to the
specified torque in two stages (1/2 then full NOTICE
torque). See Special Torque Chart on
Do not allow the connecting rod to contact the
page 6-17 for specifications.
crankshaft journal during piston installation. Damage
to the crankshaft bearing journal may result.

1. Lubricate the piston, piston rings, and cylinder

2 with clean engine oil or assembly lubricant.
2. Rotate the crankshaft so the crankpin for the
piston being installed is near bottom dead
center.

NOTICE
1
Ensure the piston ring gaps are located correctly
(Figure 6-94).

3
K0001752A 1

Figure 6-92
6. Rotate the crankshaft to assure it turns freely. 2
7. Apply ThreeBond Liquid Gasket No. 1207F,
Part No. YM977770-1207F to the mounting 3
flange of the seal housing (Figure 6-93, (2)).
8. Align the seal housing with the two dowel pins.
9. Reinstall seal housing and seal assembly.
1 – Top compression ring end gap
10. Reinstall the flywheel (Figure 6-93, (1)) and 2 – Second compression ring end gap
tighten the bolts to the specified torque. See 3 – Oil ring end gap
Special Torque Chart on page 6-17 for
specifications. Figure 6-94
3. Using a piston ring compressor, compress the
piston rings.

2 NOTICE
3 The piston and connecting rod must be installed
in the correct orientation.
1

Piston orientation to cylinder

Figure 6-93 All this
Orient the piston identification mark stamped
series
on top of the piston on the fuel injection pump
engine
side of the engine
models

6-64 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE
Piston installation - all this series engine 4. Reinstall the bearing inserts (Figure 6-96, (1))
models in the connecting rod and cap.
When correctly assembled, the piston 5. Apply a liberal coat of clean engine oil to the
identification mark (Figure 6-95, (2)) stamped bearing inserts and crankshaft journal.
into the top of the piston will be on the same side 6. Apply a light coat of clean engine oil to the rod
of the connecting rod as the match marks cap bolts. Reinstall the connecting rod cap
(Figure 6-95, (4)) stamped into the connecting (Figure 6-96, (2)). Tighten the connecting rod
rod and connecting rod cap. bolts to the specified torque in two stages (1/2
then full torque). See Special Torque Chart on
When installed in the cylinder, the piston page 6-17 for specifications.
identification mark (Figure 6-95, (2)) stamped
on the top of the piston must face the fuel
injection pump side (Figure 6-95, (1)) of the
engine and the embossed mark on the
connecting rod (Figure 6-95, (3)) must face the
flywheel end (Figure 6-95, (5)) of the engine.

6 1
1

2 2
5

3
K0001965

4 Figure 6-96
K0001967 7. Reinstall the remaining pistons in their
respective cylinders.
1 – Fuel injection pump side of engine
2 – Piston identification mark
3 – Embossed mark on connecting rod
4 – Rod and cap match marks
5 – Flywheel end of engine
6 – Camshaft side of engine
Figure 6-95

86E-7 – 98E-7 Series 6-65

ENGINE Crankshaft and Camshaft Components

Reassembly of Camshaft and Timing ■ Installation of camshaft

Components Note: The gear housing or front plate must be
reinstalled prior to installing the camshaft.
■ Installation of gear case See Installation of gear case on page 6-66.
1. If removed, install a new camshaft bushing 1. If removed, reinstall the camshaft end plate
(Figure 6-97and Figure 6-98, (3)) using the (Figure 6-99, (1)), key, and timing gear
appropriate service tool. (Figure 6-99, (4)) onto the camshaft using a
2. Apply a continuous bead of ThreeBond Liquid press.
Gasket No. 1207F, Part No. YM977770-1207F Note: Heat the gear to 356 - 392 °F (180 - 200
to the mounting area of the gear case. Be sure °C) and press onto the end of the
to circle each bolt hole. camshaft.
3. 4D98E-7, S4D98E-7: Install two new O-rings 2. Rotate the cylinder block so that gravity will
(Figure 6-97, (2)) and two pins keep the tappets (Figure 6-99, (5)) in place and
(Figure 6-97, (4)) in the cylinder block. out of the way of the camshaft lobes when the
camshaft is being reinstalled.
Note:
1 • If the engine is not installed on an engine repair
3
fixture, stand the engine upright on the flywheel
end mounting flange.
• The tappets are “mushroom” shaped and must
4 be installed from inside the engine crankcase.
3. Lubricate the tappets with clean oil or assembly
2 lube. Reinstall the tappets in their respective
061233-00X00
locations in the cylinder block. Push the tappets
fully into the tappet bores so they will not
Figure 6-97 interfere with the installation of the camshaft.
4. Lubricate the camshaft (Figure 6-99, (2)) with
4. 3D88E-7 - S4D86E-7: Reinstall the dowels
clean engine oil or assembly lube. Slowly insert
(Figure 6-98, (4)) and two new O-rings
the camshaft through the front of the engine.
(Figure 6-98, (2)).
5. Reinstall and tighten the cap screws
(Figure 6-99, (3)).
3
4
1

2 5

2 3 4
4
043961-00X02

Figure 6-98 K0001966

5. Reinstall the gear case (Figure 6-97, (1)) or

front plate (Figure 6-98, (1)). Tighten the bolts Figure 6-99
to the specified torque.

6-66 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE
■ Installation of timing gears 3. Lubricate the idler gear (A) (Figure 6-102, (2)),
1. Set the piston of gear case side cylinder bushing (Figure 6-102, (3)) and idler gear shaft
(cylinder No. 3 for three-cylinder engine, (Figure 6-102, (1)) with clean engine oil.
cylinder No. 4 for four-cylinder engine) to the
top dead center position. 2

2. Rotate the camshaft until the mark 3

1
(Figure 6-100, (C)) is approximately at the 9
o’clock position.

1 2 3 4

6
D D 5
B
B C C 4
B 3
A 1
A 5
043957-01X00

6 1 – Idler gear shaft

2 – Idler gear (A)
7
3 – Idler gear bushing
043953-01X00
4 – Idler gear (B)
1 – Supply pump gear 5 – Plate, idle shaft
2 – Idler gear (B) 6 – Packing
3 – Idler gear (A) Figure 6-102
4 – Camshaft gear
5 – Crankshaft gear 4. Align the timing gears as shown in
6 – Lubricating oil pump gear (Figure 6-100).
7 – Direction of rotation
5. Install the idler gear (A), idler gear shaft, and
Figure 6-100 idler gear bushing while aligning the timing
marks A and C. At this time, direct the punch
Figure 6-100 shows a gear train of 3D88E-7-
mark on the idler gear shaft end surface to the
S4D86E-7, the lubricating oil pump gear is driven
upper part of the engine.
from the crankshaft gear. For 4D98E-7/S4D98E-
7, it is driven from the idler gear (A) as shown in 6. While aligning the timing marks B and D of the
the Figure 6-101. idler gear (B), install the idler gear (B), idler
gear shaft, and idler gear bushing.
1 2 3 4 7. When all gears are properly aligned, tighten the
idler gear retaining bolts to specified torque.
See Special Torque Chart on page 6-17 for
specifications.

■ Installation of gear case cover

1. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1207F, Part No. YM977770-1207F
6 to the mounting area of the gear case cover
5
(Figure 6-103, (1)). Be sure to circle the bolt
7
holes.
043953-00X01

1 – Supply pump gear

2 – Idler gear (B)
3 – Idler gear (A)
4 – Camshaft gear
5 – Crankshaft gear
6 – Lubricating oil pump gear
7 – Direction of rotation
Figure 6-101

86E-7 – 98E-7 Series 6-67

ENGINE Crankshaft and Camshaft Components

2. Reinstall and tighten the gear case cover bolts. ■ Installation of oil pan
1. Reinstall the oil pickup tube (Figure 6-105, (1))
using a new O-ring (Figure 6-105, (2)).

K0001641A
2
Figure 6-103 1
3. Reinstall the crankshaft pulley.

NOTICE
Use the crankshaft pulley installation tool K0001696A

(Figure 6-104, (3)) when reinstalling the pulley

Figure 6-105
(Figure 6-104, (1)). The tool will guide the pulley
hub and protect the front seal (Figure 6-104, (2)) 2. Apply a continuous bead of ThreeBond Liquid
from damage. Gasket No. 1207F, Part No. YM977770-1207F
to the mounting surface of the oil pan
(Figure 6-106, (1)). Be sure to circle each bolt
hole.
1 3. Reinstall the oil pan and tighten the bolts
2
securely.

3 1

K0002133

Figure 6-104 K0001695A

4. Reinstall the washer and bolt. Tighten the bolt

Figure 6-106
to the specified torque. See Special Torque
Chart on page 6-17 for specifications.

6-68 86E-7 – 98E-7 Series

 Crankshaft and Camshaft Components ENGINE
Final Reassembly of Engine
1. Reinstall the starter motor.
2. Reinstall the cylinder head. See Reassembly of
cylinder head on page 6-39.
3. Reinstall the engine in the machine.
4. Reconnect the fuel and coolant lines.
5. Reinstall the alternator.
6. Reconnect all electrical connections.
7. Fill the engine with oil and coolant.
8. Reconnect the battery cables, negative (-)
cable last.

86E-7 – 98E-7 Series 6-69

ENGINE EGR System

EGR SYSTEM
EGR System (Typical Model)

1 2 3 4
043960-01X00

1 – Exhaust manifold 3 – EGR valve

2 – EGR pipe 4 – Intake manifold
Figure 6-107

6-70 86E-7 – 98E-7 Series

 EGR System ENGINE
Typical Model for Turbocharger Model

1
6

2
7
3

4 8

5
9

10

11
043962-00X00

1 – Exhaust manifold 7 – Spacer, EGR lead valve

2 – Elbow, EGR cooler inlet 8 – Lead valve, EGR
3 – EGR cooler 9 – Turbocharger
4 – Intake throttle valve 10 – Cooling water hose, EGR cooler inlet
5 – EGR valve 11 – Cooling water hose, EGR cooler outlet
6 – Intake manifold
Figure 6-108

86E-7 – 98E-7 Series 6-71

ENGINE EGR System

Disassembly of Supply Pump WARNING

DANGER Entanglement Hazard!
Scald Hazard! • Stop the engine before you begin
to service it.
• Never remove the radiator cap if
the engine is hot. Steam and hot
engine coolant will spurt out and
seriously burn you. Allow the
engine to cool down before you • Never leave the key in the key switch when
attempt to remove the radiator you are servicing the engine. Someone may
cap. accidentally start the engine and not realize
you are servicing it. This could result in a
• Tighten the radiator cap securely after you
serious injury.
check the radiator. Steam can spurt out
during engine operation if the cap is loose. • If you must service the engine while it is
operating, remove all jewelry, tie back long
• Always check the level of the engine coolant
hair, and keep your hands, other body parts
by observing the reserve tank.
and clothing away from moving / rotating
• Failure to comply will result in death or parts.
serious injury.
• Failure to comply could result in death or
serious injury.
WARNING
Burn Hazard! WARNING
• Keep your hands and other body Fume/Burn Hazard!
parts away from hot engine
• Always read and
surfaces such as the muffler,
follow safety related
exhaust pipe, turbocharger (if
precautions found on
equipped) and engine block
containers of
during operation and shortly after
hazardous substances
you shut the engine down. These
like parts cleaners,
surfaces are extremely hot while
primers, sealants and
the engine is operating and could
sealant removers.
seriously burn you.
• Failure to comply could result in death or
• Failure to comply could result in death or
serious injury.
serious injury.

6-72 86E-7 – 98E-7 Series

 EGR System ENGINE

CAUTION NOTICE
Flying Object Hazard! When it is necessary to replace an EGR valve, be
• Always wear eye protection when sure to replace the entire EGR valve assembly.
servicing the engine and when Neither attempt to disassemble and repair the EGR
using compressed air or high- valve, nor replace its individual components.
pressure water. Dust, flying
debris, compressed air, NOTICE
pressurized water or steam may The EGR system uses steel gaskets at the joints
injure your eyes. between its components/parts. These steel gaskets
• Failure to comply may result in minor or are specific to the respective joints. When you
moderate injury. remove the system’s components/parts and
reinstall them, replace the steel gaskets between
CAUTION them with new correct ones.
Coolant Hazard!
• Wear eye protection 1. Remove the air cleaner if an air cleaner is equipped
and rubber gloves on the EGR valve.
when you handle non- 2. EGR valve is in a closed state when the key
amine engine coolant switch is turned off. In order to clean the valve,
(AF-NAC). If contact ECU sends signals to EGR, and forcibly fully
with the eyes or skin opens the EGR valve. Therefore, do not
should occur, flush disconnect the wire harness when you remove
eyes and wash the EGR valve from the engine. However, if it is
immediately with difficult to remove the EGR valve from the
clean water. engine with the wire harness being connected,
• Failure to comply may result in minor or disconnect the wire harness first and remove
moderate injury. the EGR valve. After removing the EGR valve,
reconnect the wire harness to the engine.
3. Use a special wire harness if you want to remove the
EGR valve farther from the engine for efficient
cleaning. (See Figure 6-109)

SA-D
Active control

Engine harness

ECU

Engine

Harness for EGR valve cleaning

EGR valve

055189-00EN00

Figure 6-109

86E-7 – 98E-7 Series 6-73

ENGINE EGR System

■ Engine without turbocharger (3D88E-7,

4D88E-7, 4D98E-7)
1. Loosen the nuts in the coupling flanges of the
exhaust manifold and the EGR pipe.
1
2. Loosen the bolts in the coupling flanges of the
EGR pipe and EGR valve, and remove the
EGR pipe. 2

3
043970-00X00

1 – EGR pipe
2 – Bend (EGR cooler out)
3 – EGR cooler
Figure 6-111

■ EGR active control

1 2 043963-00X00 Connect the SMARTASSIST DIRECT (SA-D) to the
engine wire harness.
1 – Connecting pipe (EGR out)
2 – EGR pipe • Before forcibly activating the EGR, check for
Figure 6-110 errors that affect the fully closing process of the
EGR.
3. Remove the EGR valve. How to check: Press “Defect Display” and
“Current Defect”. If the error is displayed,
■ Engine with turbocharger (S3D86E-7, go to (1). If no error is displayed, go to (2).
S4D86E-7, S4D98E-7)
(1)
1. Disconnect the cooling water inlet and outlet
hoses from the EGR cooler by loosening the • Select “Diagnostic Codes” and select “Defect
hose clips. History”
When loosening the clips, put waste cloth or the • Press “All Clear” button
like beneath the hose joints in case water leaks.
• Error information is cleared from the “Defect
2. Loosen the nuts used to connect the exhaust History”
manifold with the EGR cooler elbow.
(2)
3. Loosen the bolts in the coupling flanges of the
EGR cooler and EGR pipe, and remove the • Select “Diagnosis Tests” and select “Active
EGR cooler. Control”
4. Remove the elbow from the EGR cooler. • Press “Execute” button from “EGR Valve
Opening Control”
5. Remove the EGR pipe from the EGR valve.
• Enter the user ID and password
6. Remove the EGR valve.
• When “EGR Valve Opening Control” is
7. Remove the spacer (for the lead valve).
displayed, enter “106” in “Desired” and press
8. Remove the lead valve. “Set”
• Active control starts if no error is found
• Check that the desired value on the screen
indicates the set target value. EGR valve opening
control lamp comes on.

6-74 86E-7 – 98E-7 Series

 EGR System ENGINE
Remove the remaining carbon deposits by blowing
NOTICE the compressed air. (Figure 6-112)
Do not end the SA-D while cleaning the EGR.

For details on how to operate the EGR Active

Control, refer to the SMARTASSIST DIRECT (SA-
D) Operation Manual.

Cleaning the EGR Valves

WARNING
Fume/Burn Hazard!
• Always read and
follow safety related
precautions found on
containers of
hazardous substances
like parts cleaners,
primers, sealants and Carbon removal
sealant removers.
• Failure to comply could result in death or
serious injury.

CAUTION
Flying Object Hazard!
• Always wear eye protection when
servicing the engine and when
using compressed air or high- Care must be taken for the direction
of air blow not to catch the carbon
pressure water. Dust, flying in this part.
debris, compressed air, 055190-00EN00

pressurized water or steam may

Figure 6-112
injure your eyes.
• Failure to comply may result in minor or ■ Exit the EGR active control
moderate injury. You can exit the EGR Active Control from the
SMARTASSIST DIRECT screen.
Clean the EGR valve every 3000 hours of • Press the “Stop” button from “EGR Valve
operation to prevent carbon deposits. This leads to Opening Control”.
deterioration of EGR performance. Blow the carbon
deposits with the compressed air (0.19 MPa (2 • EGR valve opening control lamp goes off and
kg/cm2) or less). Use a soft brush with carbon EGR Active Control exits.
cleaner or kerosene to clean the EGR valve if the
EGR valve is excessively dirty. Be sure to remove ■ Precautions for cleaning
all carbon deposits. (Figure 6-112) • Do not disassemble the EGR valve.
In this case, the motor portion and the coupler • Do not use wash fluid.
terminals should not be exposed to solvent or
cleaner. This may result in a malfunction. • Do not use a hard brush made of metal.

If the carbon deposits can not be removed by a • Clean entire circumference of the valve and the
brush, be sure to replace the entire EGR valve valve seat, and blow with the compressed air.
assembly. • Do not put your fingers into the valve portion.

86E-7 – 98E-7 Series 6-75

ENGINE EGR System

Clean Lead Valves Precautions for Installation

Similarly to the EGR valves, the lead valves must 1. The valve and stopper must be installed in their
be periodically cleaned every 3000 hours because, specific orientations. As shown in the figure
as exhaust gas circulates through them for a above, install the valve and stopper so that they
prolonged time, carbon is deposited on their inner are located on the left-hand side of the lead
surfaces, possibly deteriorating the EGR ratio. valve.
To remove carbon deposited inside the lead valves, 2. Install the valve by tightening the machine
disassemble and clean them. screw while ensuring that it is evenly positioned
inside the case window.
3. The machine screw must be tightened with
torque of 1.37 ± 0.2 N·m (14 ± 2 kgf·cm).
4. After tightening the machine screw, mark it with
1 a marker to indicate that it has already been
tightened.
2
Clean EGR Cooler
3 4
The EGR cooler must be periodically cleaned every
1 – Case 3000 hours because the exhaust gas passage is
2 – Stopper subject to carbon deposition and the cooling water
3 – Valve transit portion to scale deposition and these
4 – Machine screw depositions gradually deteriorate the cooling of
Figure 6-113 recirculated gas, thus resulting in higher gas
temperatures and lower effective circulation
To remove deposited carbon, use carbon cleaner, amounts (EGR ratio).
kerosene, or some other liquid capable of removing
carbon as well as a soft brush or cloth to clean the To remove deposited carbon from the gas passage,
valves, taking care not to damage their parts. use compressed air (0.19 MPa (2 kg/cm2) or lower).
Then dip the gas passage in carbon cleaner,
Upon completion of carbon removal, wipe off water kerosene, or some other liquid capable of removing
and liquid, make sure that the case, valve, and carbon; leave it dry and blow it with compressed air
stopper are free of foreign matter, and then reinstall again.
the valve and related parts.
To clean the water transit portion, dip it in a solution
of descaling detergent diluted with water and wash
it.

Stopper chamfer

Exhaust gas
passage hole 17.5

Assemble without
misalignment.
20 Valve plate

Figure 6-114

6-76 86E-7 – 98E-7 Series

 EGR System ENGINE
EGR Pipe and Other Connecting
Elbows
The exhaust gas passage is subject to carbon
deposition when used over time. To remove
deposited carbon from the gas passage, use
compressed air (0.19 MPa (2 kg/cm2) or lower). If
the exhaust gas passage is heavily fouled, clean it
by dipping it in carbon cleaner, kerosene, or some
other liquid capable of removing carbon.

NOTICE
• Always be environmentally
responsible.

• Follow the guidelines of the EPA or other

governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.

Installing EGR Related

Components/Parts
To install these components/parts, reverse the
disassembly procedure described above: thus
install the lead valve, spacer, EGR valve, EGR
pipe, EGR cooler, elbow, cooler cooling water hose,
and EGR cooling water hose exactly in this order.
The EGR system uses steel gaskets at the joints
between its components/parts. When you remove
the system’s components/parts and reinstall them,
replace the steel gaskets between them with new
correct ones.

86E-7 – 98E-7 Series 6-77

ENGINE Intake Throttle

INTAKE THROTTLE
The intake throttle is a device that controls the • Prevent water and foreign matter from entering
amount of the engine air intake. This series engines the connector connection part.
use it for the combustion of soot collected inside
the KDPF. The intake throttle is driven by the DC Characteristics of the intake throttle
motor. The ECU controls the appropriate degree of
Fully closed angle flow
opening of the throttle depending on the engine rate before adjustment
Fully closed learning
speed and load conditions. Accordingly, the engine Mechanical valve position Fully closed
takes in the minimum required amount of air to operating angle adjustment angle
increase the exhaust temperature and burn soot Mechanical valve Fully closed control
maximum 4° angle
inside the KDPF. operating angle 3.18° Excluding overshoot,
undershoot and the
1°MIN
Check the operation performance of the intake dispersion in the

5°
10
1.6 system side

2°
throttle very 3000 hours of operation. It is

.8
°
8Max

2
94
.8
82
necessary to connect SMARTASSIST DIRECT for
the EGR valve cleaning. For details, refer to the ax
9M
SMARTASSIST DIRECT Operation Manual. Valve R2

ø1
closing

ø55 + 0.1
direction

ø56± 0.5
0
Precautions for Handling the Intake 5
0.
Throttle C

Fully open control

• Do not use a throttle after you have dropped it. position
Even if it appears okay on the outside, it may Maintain 9.88 degrees or more from Valve fly-out range
the fully open position of machine
have internal damage. (Excluding overshoot, undershoot and
the dispersion in the system side) 044868-00EN00
• Do not apply excessive impact or load to the
throttle. Figure 6-115
• Do not touch the stop screw part, as it has
already been adjusted. Characteristics graph
VT A 1 (0.040V/2)
• Prevent any foreign matter including oil, dust, and (V)
water droplets from entering the air passage part. Output voltage
5
• Do not remove the sensor cover installation rivet. DC5V impressed 4
Between VC-E2
• Consider static electricity and prevent static 3
electric charge of the human body when handling 2
the throttle. 1

• Do not touch the sensor cover terminal directly. 0.600V 0

20 40 60 80 95
Fully open
Fully closed

Valve opening (°)

• Do not touch the throttle valve with your hands
when the throttle is energized. 95°(Mechanical (98°: Before
Your hands may get pinched in the valve and get operating angle) adjustment)
injured. 044867-00EN00

• Do not check operation with the installation Figure 6-116

surface of the throttle unit pointing down, as the
valve protrudes from the installation surface.

6-78 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 7

FUEL SYSTEM
Page
Before You Begin Servicing ................................................................... 7-3
System Structure.................................................................................... 7-4
Fuel System Specifications .................................................................... 7-6
Torque Chart for Major Bolts and Nuts............................................. 7-6
Fuel System Diagram............................................................................. 7-7
Fuel System Components ...................................................................... 7-8
Removal of Common Rail ................................................................ 7-9
Reassembly of Common Rail......................................................... 7-10
Removal of Injector ........................................................................ 7-11
Reassembly of injector ................................................................... 7-12
Removal of Supply Pump............................................................... 7-13
Reassembly of Supply Pump ......................................................... 7-14

86E-7 – 98E-7 Series 7-1

FUEL SYSTEM

7-2 86E-7 – 98E-7 Series

Before You Begin Servicing FUEL SYSTEM

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.

86E-7 – 98E-7 Series 7-3

FUEL SYSTEM System Structure

SYSTEM STRUCTURE
Fuel feed pump Rail pressure sensor Rail Relief valve
(mechanical)

Supply pump Main filter

Intake metering
valve

Fuel feed pump

(electromagnetic)
Fuel cooler
Pre-filter Crank speed sensor Injector

ECU
Gear speed sensor

Fuel tank Accelerator sensor

Flow of intake
Flow of injection fuel Flow of electrical signal
/return fuel
037193-00E00

Figure 7-1

■ Supply pump
The fuel passes the pre-filter and is pressure-fed by a fuel feed pump to the main filter, then it arrives at the
supply pump. The ECU controls the opening of the intake metering valve and adjusts the fuel intake
volume so that the rail pressure is at the target value. The fuel pressurized in the supply pump is fed to the
rail.

■ Rail
A pressure of up to 160 MPa is accumulated in the rail. The rail is equipped with a rail pressure sensor and
it sends information to the ECU. In the case of an abnormal increase in the rail pressure, the mechanical
relief valve opens to prevent the pressure increase.

■ Injector
The ECU controls the injector to maintain optimum injection volume and injection timing, and injects the
high pressure fuel accumulated in the rail into the cylinder.
Each injector has its unique correction data to optimize the injection volume. The correction data can be
found on the top of the injectors. The correction data is written to the ECU, and the ECU corrects the
injection volume based on the correction data. Therefore, it is necessary to write the correction data to the
ECU when the injector or ECU is replaced. For details, refer to the SMARTASSIST DIRECT (SA-D)
Operation Manual. Never touch the electric wiring with your hands when the key switch is in the “ON”
position. High-voltage current flows in the injector.

7-4 86E-7 – 98E-7 Series

System Structure FUEL SYSTEM
■ Crank rotation sensor and gear speed sensor
The crank rotation sensor is equipped on the flywheel side and the gear speed sensor is equipped on the
gear side. Based on these 2 sensor outputs, the ECU recognizes the engine speed and each piston
position.

■ ECU
Based on the information from each sensor, ECU determines optimum injection volume, injection timing
and rail pressure, and controls the intake metering valve of the supply pump and injector. It also monitors
the occurrence of system abnormality at all times. If an abnormality is detected, it notifies the operator and
controls the safe running condition of the system.

86E-7 – 98E-7 Series 7-5

FUEL SYSTEM Fuel System Specifications

FUEL SYSTEM SPECIFICATIONS

Torque Chart for Major Bolts and Nuts
Thread diameter and Lubricating oil application
Component Tightening torque
pitch (Thread portion and seat surface)
18.0 - 20.9 ft·lb
Fuel injector retainer bolt M8 × 1.25 mm (24.4 - 28.4 N·m; Not applied
2.5 - 2.9 kgf·m)
55.3 - 62.7 ft·lb
Supply pump drive gear nut M18 × 1.5 mm (75 - 85 N·m; Not applied
7.6 - 8.7 kgf·m)
21.7 - 25.3 ft·lb
M12 × 1.5 mm
(29.4 - 34.3 N·m; Not applied
(Rail)
3.0 - 3.5 kgf·m)
19.5 - 23.2 ft·lb
M12 × 1.5 mm
Fuel high pressure pipe nut (26.5 - 31.4 N·m; Not applied
(Injector)
2.7 - 3.2 kgf·m)
21.7 - 25.3 ft·lb
M16 × 1.0 mm
(29.4 - 34.3 N·m; Not applied
(Supply pump)
3.0 - 3.5 kgf·m)
9.4 - 12.3 ft·lb
M8 (12.7 - 16.7 N·m; Not applied
1.3 - 1.7 kgf·m)
14.5 - 18.7 ft·lb
M10 (19.6 - 25.4 N·m; Not applied
2.0 - 2.6 kgf·m)
18.1 - 25.3 ft·lb
Ball joint bolt M12 (24.5 - 34.3 N·m; Not applied
2.5 - 3.5 kgf·m)
28.9 - 36.1 ft·lb
M14 (39.2 - 49.0 N·m; Not applied
4.0 - 5.0 kgf·m)
36.1 - 43.4 ft·lb
M16 (49.0 - 58.8 N·m; Not applied
5.0 - 6.0 kgf·m)
7.2 - 8.7 ft·lb • Apply 80 % torque when tightened
M6 × 1.0 mm (9.8 - 11.8 N·m; to aluminum alloy.
1.0 - 1.2 kgf·m) • Apply 60 % torque for 4T and
check nut.
16.6 - 20.9 ft·lb
M8 × 1.25 mm (22.6 - 28.4 N·m;
2.3 - 2.9 kgf·m)
Hexagon bolt (7T) and nut
32.5 - 39.8 ft·lb
M10 × 1.5 mm (44.1 - 53.9 N·m;
4.5 - 5.5 kgf·m)
57.8 - 72.3 ft·lb
M12 × 1.75 mm (78.4 - 98 N·m;
8.0 - 10.0 kgf·m)

7-6 86E-7 – 98E-7 Series

Fuel System Diagram FUEL SYSTEM

FUEL SYSTEM DIAGRAM

Pressure sensor
Rail
Pressure control valve

Supplier pump

Fuel filter

Fuel feed pump

Injectors
Fuel filter/water Various sensors
separator

Fuel tank
Engine Engine Accelerator Turbocharger Intake Cooling
ECU speed speed pedal boost temperature water
(crank) (cam) temperature

EGR
Starting aid
Starter
Instrument panel 038347-00E02

Figure 7-2

86E-7 – 98E-7 Series 7-7

FUEL SYSTEM Fuel System Components

FUEL SYSTEM COMPONENTS

11

12

10

7
6
9

043937-01X00

1 – High-pressure fuel injection lines 7 – Fuel supply pump drive gear

(Common rail - Injector) 8 – Supply pump
2 – Fuel return line 9 – Fuel filter
3 – Fuel injector 10 – Fuel filter housing
4 – Gear case 11 – Common rail
5 – Gear case cover 12 – High-pressure fuel injection lines
6 – Fuel supply pump drive gear nut (Supply pump - Common rail)
Figure 7-3

7-8 86E-7 – 98E-7 Series

Fuel System Components FUEL SYSTEM
Removal of Common Rail 4. Remove the fuel return hose from the injector.
Pull out the fuel return hose connector (back
1. Remove the wiring of the injector coupler on the leak rail connector) (Figure 7-7, (2)) vertically
injector. while fully pressing the retaining ring (clip)
(Figure 7-7, (1)) attached on the top of the
injector in the direction of the arrow A
(Figure 7-7). Do not hold the hose. This may
damage the hose. Do not reuse the removed
clips.

2
1

A
043938-00X01

Figure 7-4

045207-00X01

Figure 7-7
5. Removal of high-pressure pipe (1)
(Common rail - injector)
1- Clean around the cap nuts on both the
injector and rail sides, using a brush or
aspirator.
043939-00X01

Figure 7-5
2. Remove the wiring coupler of the pressure
sensor (Figure 7-6, (3)).

1
2
3

043942-00X01

043940-00X02
Figure 7-8

Figure 7-6 2- Loosen the cap nut of the high-pressure pipe

on the injector side (Figure 7-9, (4)). When
3. Remove the leak piping (Figure 7-6, (2)) from loosening the cap nut, hold the inlet
the pressure limiter (Figure 7-6, (1)). connector of the injector (Figure 7-9, (3))
using a spanner (Figure 7-9, (1)) or other
tool so as not to rotate the connector
together.

86E-7 – 98E-7 Series 7-9

FUEL SYSTEM Fuel System Components

Reassembly of Common Rail

1 2 3 4
1. Reassembly of common rail body
Temporarily tighten the 2 pieces of M8 bolts by
hand while securely holding the common rail
body by hand. Then, tighten the bolts to
specification.

16.7 - 20.9 ft·lb

Tightening torque
(22.6 - 28.4 N·m;
for M8 bolts
2.3 - 2.9 kgf·m)
061319-00X00
2. Reassembly of high-pressure pipe (1)
Figure 7-9 (Common rail - injector)

3- Next, while pressing and holding the pipe CAUTION

against the bearing surface by hand, loosen
the cap nut of pipe on the rail side For high-pressure pipe, use a new one. If you
(Figure 7-9, (2)) using a tool. reuse it, the displacement of the working face
may occur, causing the fuel leaks.
4- Finally, while pressing the pipes of the
injector side and the rail side respectively
against the bearing surface by hand, loosen 1- Before reinstalling the high-pressure pipe,
and remove the cap nut by hand. apply fuel to the cap nut thread portion.
5- Remove the high-pressure pipe. 2- Temporarily tighten the clamp of the pipe.
6- Clean the removed seat portions of the 3- Securely seat and fix the pipe of the injector
injector with an aspirator or the like and side on the seat part by hand in advance,
cover them with a vinyl bag. and temporarily tighten the cap nut by hand.
6. Removal of high-pressure pipe (2) 4- Next, securely seat and fix the pipe of the rail
(Supply pump - common rail) side on the seat part by hand, and
1- Clean around the cap nuts on both the pump temporarily tighten the cap nut so as to
and rail sides, using a brush or aspirator. rotate smoothly by hand.
2- While pressing and holding the pipes of the 5- Fully tighten the clamp.
rail and pump sides respectively against the 6- While holding the inlet connector of the
bearing surface by hand, loosen the cap nut injector side using a spanner or other tool,
using a tool. tighten the cap nut to the specified torque.
3- After that, while pressing the pipes of the rail 7- Finally tighten the cap nut of the rail side to
and pump sides respectively against the the specified torque.
bearing surface by hand, loosen and remove
the cap nut by hand. 19.5 - 23.2 ft·lb
Tightening torque
(26.5 - 31.4 N·m;
4- Remove the high-pressure pipe. for cap nut (injector side)
2.7 - 3.2 kgf·m)
5- Clean the removed seat portions of the rail 21.7 - 25.3 ft·lb
inlet with an aspirator or the like and cover Tightening torque
(29.4 - 34.3 N·m;
them with a vinyl bag. for cap nut (rail side)
3.0 - 3.5 kgf·m)
7. Removal of common rail
Remove the 2 pieces of M8 bolts that attach the 3. Reassembly of high-pressure pipe (2)
common rail, and remove the rail body. (Supply pump - common rail)

NOTICE CAUTION
• Loosen the bolts while securely holding the For high-pressure pipe, use a new one. If you
rail body by hand not to drop it. reuse it, the displacement of the working face
may occur, causing the fuel leaks.
• Hold the rail body without touching the
sensors.

7-10 86E-7 – 98E-7 Series

Fuel System Components FUEL SYSTEM
1- Before reinstalling the high-pressure pipe, 9. Replace attached parts of the rail
apply fuel to the cap nut thread portion. Spare parts for the rail pressure sensor
2- Securely seat and fix the pipes of the pump (Figure 7-11, (1)) and the pressure limiting
and rail sides respectively on the seat part valve (Figure 7-11, (2)) are available for
by hand, and temporarily tighten the cap nut replacement. See the below table for the part
so as to rotate smoothly by hand. number and the tightening torque.
3- Tighten the cap nuts to specification. Tightening
Part name Part No.
torque
Tightening torque 66.4 - 73.8 ft·lb
for cap nut (rail side) 21.7 - 25.3 ft·lb Rail pressure YM129A00-
(90 - 100 N·m;
(29.4 - 34.3 N·m; sensor 57100
Tightening torque 9.2 - 10.2 kgf·m)
3.0 - 3.5 kgf·m)
for cap nut (pump side) 70.1 - 77.4 ft·lb
Pressure limiting YM129A00-
(95 - 105 N·m;
valve (with O-ring) 57200
4. Be sure the new O-rings are installed on the 9.7 - 10.7 kgf·m)
valve cover nuts. O-ring for pressure YM129A00-
–
Reinstall and tighten the valve cover nuts. limiting valve 57210

5. Press in the connector vertically from above

while fully pressing the retaining ring of the 2
injector in the direction of the arrow A. At this
time, apply kerosene to the O-ring.

A 1

055191-00X00

045206-00X01
Figure 7-11
Figure 7-10
Removal of Injector
6. Reinstall the leak piping from the pressure
1. Remove the wiring of the injector coupler on the
limiter.
injector and move it to a place where it won’t
interfere the operation.
NOTICE
2. Remove the fuel return pipe. At this time,
Do not reuse the gaskets. remove the fuel return pipe connector vertically
while pressing the retaining ring.
7. Reinstall the wiring coupler of the pressure 3. Removal of high-pressure pipe
sensor. (Common rail - injector)
8. Reinstall the injector wiring coupler. 1- Clean around the cap nuts on both the
injector and rail sides, using a brush or
aspirator.

86E-7 – 98E-7 Series 7-11

FUEL SYSTEM Fuel System Components

2- Loosen the cap nut of the high-pressure pipe Reassembly of injector

on the injector side (Figure 7-12, (4)). When
loosening the cap nut, hold the inlet 1. Reassembly of injector
connector of the injector (Figure 7-12, (3)) Insert the injector into the head by using the
using a spanner (Figure 7-12, (1)) or other new injector seat (gasket).
tool so as not to rotate the connector
together.
NOTICE
• If you reuse the injector, be sure to reinstall it
1 2 3 4 to the original cylinder.
• When replacing the injector, replace it in the
assembly.
• If you replace the injector, it is required to
write the correction value of each injector to
E-ECU.
• If rewriting is not correctly done, the engine
performance cannot be guaranteed.
061319-00X00
• Rewrite the correction value using
Figure 7-12 SMARTASSIST DIRECT(SA-D).

3- Next, while pressing and holding the pipe • The correction value is written on the injector.
against the bearing surface by hand, loosen
the cap nut of pipe on the rail side
(Figure 7-12, (2)) using a tool. 2. Reassembly of injector fixture retainer
4- Finally, while pressing the pipes of the 1- Reinstall the injector fixture retainer.
injector side and the rail side respectively Temporarily tighten the bolt by hand at this
against the bearing surface by hand, loosen time.
and remove the cap nut by hand. 3. Reassembly of high-pressure pipe
5- Remove the high-pressure pipe. (Common rail - injector)
6- Clean the removed seat portions of the
injector with an aspirator or the like and
CAUTION
cover them with a vinyl bag. For high-pressure pipe, use a new one. If you
4. Loosen the injector fixture retainer bolt (M8), reuse it, the displacement of the working face
and remove the retainer. may occur, causing the fuel leaks.
5. Remove the injector and injector seats
(gaskets). 1- Before reinstalling the high-pressure pipe,
apply fuel to the cap nut thread portion.
NOTICE
2- Temporarily tighten the clamp of the pipe.
• Do not reuse the injector seats (gaskets).
3- Securely seat and fix the pipe of the injector
• Separate the injectors by each cylinder (mark side on the seat part by hand in advance,
them). and temporarily tighten the cap nut by hand.
4- Next, securely seat and fix the pipe of the rail
• Clean the removed injectors and cover them
side on the seat part by hand, and
with a vinyl bag.
temporarily tighten the cap nut so as to
• Never disassemble the injector. If you change rotate smoothly by hand.
the injector to the new one must be changed 5- Fully tighten the clamp.
with whole injector.

7-12 86E-7 – 98E-7 Series

Fuel System Components FUEL SYSTEM
4. Tighten the injector fixture retainer bolt to Removal of Supply Pump
specification.
1. Remove the wiring coupler of the fuel pressure
18.0 - 20.9 ft·lb sensor.
Tightening torque for M8
(24.4 - 28.4 N·m; 2. Remove the wiring coupler of the suction
bolts
2.5 - 2.9 kgf·m)
control valve (SCV).
5. While holding the inlet connector of the injector 3. Remove the fuel supply pipe (supply pump
side using a spanner or other tool, tighten the inlet) from the fuel filter (supply pump intake).
cap nut of the hight-pressure pipe to the
specified torque.
6. Finally tighten the cap nut of the high-pressure
pipe on the rail side to the specified torque.

19.5 - 23.2 ft·lb

Tightening torque for
(26.5 - 31.4 N·m;
cap nuts (injector side)
2.7 - 3.2 kgf·m)
21.7 - 25.3 ft·lb
Tightening torque for From fuel tank To fuel tank
(29.4 - 34.3 N·m;
cap nuts (rail side)
3.0 - 3.5 kgf·m)

Injector overflow
7. Reinstall the fuel return pipe.

NOTICE Rail overflow

At this time, insert the fuel return pipe vertically

while pressing the retaining ring. Apply light oil to
the O-ring so that it does not roll up. (Do not use
lubricating oil because alloys such as zinc are
used.) Supply pump
intake
Supply pump
overflow
8. Reinstall the wire harness with the M4 nuts.
9. Reinstall the injector wiring coupler. 043943-00E00

NOTICE Figure 7-13

• If you replace the injector, it is required to
write the correction value of each injector to NOTICE
E-ECU. The fuel in the pipe may possibly spill at this time.
Prepare a fuel container before its removal.
• If rewriting is not correctly done, the engine
performance cannot be guaranteed.
• Rewrite the correction value using Diagnostic 4. Remove the fuel return pipe (supply pump
Tool, SMARTASSIST DIRECT (SA-D). outlet) to the fuel filter (supply pump overflow).
5. Remove the return pipes from the common rail
• The correction value is written on the injector.
and injector (rail overflow and injector overflow).
• If the correction value of the injector is not
correctly written, not only the engine NOTICE
performance cannot be guaranteed, but the Do not reuse either gasket.
engine may also not comply with emission
control regulations.
6. Remove the fuel filter together with the
mounting base from the engine as required.

86E-7 – 98E-7 Series 7-13

FUEL SYSTEM Fuel System Components

7. Removal of high-pressure pipe Reassembly of Supply Pump

(Supply pump - common rail)
1. Reassembly of supply pump body
1- Clean around the cap nuts on both the pump Align the position of the supply pump drive shaft
and rail sides, using a brush or aspirator. key (pin) to the drive gear position, and reinstall
2- While pressing and holding the pipes of the the supply pump to the gear case.
rail and pump sides respectively against the Reinstall the supply pump with the 3 pieces of M8
bearing surface by hand, loosen the cap nut nuts.
using a tool.
3- After that, while pressing the pipes of the rail NOTICE
and pump sides respectively against the
bearing surface by hand, loosen and remove Be sure to apply oil to the O-ring at the time of
the cap nut by hand. installation so that is does not roll up.
4- Remove the high-pressure pipe.
5- Clean the removed seat portions of the rail 16.7 - 20.9 ft·lb
inlet with an aspirator or the like and cover Tightening torque for M8
22.6 - 28.4 N·m
them with a vinyl bag. nuts
(2.3 - 2.9 kgf·m)
8. Remove the supply pump cover (drive gear) of
the gear case. 2. With the special M18 nuts, reinstall the supply
pump drive gear to the supply pump drive shaft.
9. Remove the supply pump drive gear nut (M18).
55.3 - 62.7 ft·lb
NOTICE Tightening torque for
75 - 85 N·m
M18 nut
Be sure to put an alignment mark between the (7.7 - 8.7 kgf·m)
supply pump drive gear and the idle gear. Do not
rotate the crankshaft of the engine after putting NOTICE
the mark.
Make sure that the alignment mark with the idle
gear is not misaligned.
10. Extract the supply pump drive gear by using the
gear extraction tool. NOTICE
NOTICE Make sure that painting does not get into the
coupler while reinstalling the coupler.
Be sure to use the gear extraction tool.

3. Reinstall the supply pump cover

11. Remove the supply pump nut (M8 - 3 pieces),
and remove the supply pump. 16.7 - 20.9 ft·lb
Tightening torque for M8
22.6 - 28.4 N·m
bolts
NOTICE (2.3 - 2.9 kgf·m)

• Never disassemble the supply pump. 4. Reassembly of high-pressure pipe

• If you change the supply pump to the new one (Supply pump - common rail)
must be changed with whole pump.
CAUTION
For high-pressure pipe, use a new one. If you
reuse it, the displacement of the working face
may occur, causing the fuel leaks.

1- Before reinstalling the high-pressure pipe,

apply fuel to the cap nut thread portion.

7-14 86E-7 – 98E-7 Series

Fuel System Components FUEL SYSTEM
2- Securely seat and fix the pipes of the pump
and rail sides respectively on the seat part 1
by hand, and temporarily tighten the cap nut
so as to rotate smoothly by hand.
3- Tighten the cap nuts to specification.

Tightening torque 2
for cap nuts (rail side) 21.7 - 25.3 ft·lb
(29.4 - 34.3 N·m;
Tightening torque 3.0 - 3.5 kgf·m)
for cap nuts (pump side)

5. Reinstall the fuel filter (M10 - 2 pieces).

25.8 - 31.7 ft·lb

Tightening torque for
35 - 43 N·m
M10 bolts
(3.6 - 4.4 kgf·m)

6. Reinstall the common rail and the return pipe

from the injector.
7. Reinstall the return pipe from the supply pump. 055192-00X00

8. Reinstall the fuel supply pipe (supply pump

Figure 7-14
inlet) from the fuel filter.
9. Reinstall the wiring coupler of the fuel
temperature sensor.
10. Reinstall the wiring coupler of the SCV.

NOTICE
Be sure to perform priming the engine before
starting. If air is mixed to the fuel, seizure to the
supply pump and the injector may result.

11. Replace attached parts of the supply pump

Spare parts for the fuel temperature sensor
(Figure 7-14, (1)) and the fuel metering valve
(suction control valve) (Figure 7-14, (2)) are
available for replacement. See the below table
for the part number and the tightening torque.
Tightening
Part name Part No.
torque
19.2 - 22.1 ft·lb
Fuel temperature YM129A00-
(26 - 30 N·m;
sensor (with gasket) 51200
2.7 - 3.1 kgf·m)
Fuel metering valve
2.2 - 3.0 ft·lb
(suction control YM129A00-
(3.0 - 4.0 N·m;
valve) (with seal ring 51100
0.31 - 0.41 kgf·m)
and O-ring)
Fuel metering valve YM129A00-
–
seal ring 51110
Fuel metering valve YM129A00-
–
O-ring 51120
Fuel metering valve YM129A00-
–
fixing bolt 51130

86E-7 – 98E-7 Series 7-15

FUEL SYSTEM Fuel System Components

7-16 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 8

COOLING SYSTEM
Page
Before You Begin Servicing ................................................................... 8-3
Introduction............................................................................................. 8-4
Cooling System Diagram........................................................................ 8-4
Engine Coolant Pump Components ....................................................... 8-5
Engine Coolant System Check............................................................... 8-6
Engine Coolant Pump ............................................................................ 8-6
Removal of Engine Coolant Pump ................................................... 8-6
Disassembly of Engine Coolant Pump ............................................. 8-7
Cleaning and Inspection................................................................... 8-8
Reassembly of Engine Coolant Pump.............................................. 8-9
Installation of Engine Coolant Pump .............................................. 8-10

86E-7 – 98E-7 Series 8-1

COOLING SYSTEM

8-2 86E-7 – 98E-7 Series

Before You Begin Servicing COOLING SYSTEM

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.

86E-7 – 98E-7 Series 8-3

COOLING SYSTEM Introduction

INTRODUCTION
This section describes the procedures necessary to service the engine coolant pump. This engine coolant
pump is representative of the coolant pumps used on other model engines. For specific part detail, see the
Parts Book for the engine you are working on.

COOLING SYSTEM DIAGRAM

3
4
7

L
FUL

LOW

6
5

K0000573A-01X

1 – Cylinder head 5 – Coolant recovery tank

2 – Thermostat 6 – Engine oil cooler*1
3 – Engine coolant pump 7 – Cylinder block
4 – Radiator
Figure 8-1

*1: Not standard on all models.

8-4 86E-7 – 98E-7 Series

Engine Coolant Pump Components COOLING SYSTEM

ENGINE COOLANT PUMP COMPONENTS

1
2

3
5
4
8 14
7

9
12

10

11

13

K0000031A-01X

1 – Thermostat cover 8 – Gasket

2 – Thermostat cover gasket 9 – Engine coolant pump gasket
3 – Thermostat 10 – V-belt
4 – Thermostat O-ring 11 – Engine coolant pump V-pulley
5 – Special O-ring 12 – Spacer
6 – Engine coolant pump 13 – Engine coolant fan
7 – Temperature switch 14 – Water temperature sensor
(Electronically controlled engine)
Figure 8-2

86E-7 – 98E-7 Series 8-5

COOLING SYSTEM Engine Coolant System Check

ENGINE COOLANT SYSTEM CHECK

Check the engine coolant system for leakage.
1. With the radiator properly filled, install a cooling
system tester (Figure 8-3, (1)).
2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05
kgf/cm²) to the cooling system. If the pressure
reading drops, the engine coolant system is
leaking. Identify the source of the leak and
repair it.
1 K0000577AX

Figure 8-3

ENGINE COOLANT PUMP

Removal of Engine Coolant Pump 1. Before removing the engine coolant pump or
thermostat, it will be necessary to drain the
Verify the condition of the engine coolant pump engine coolant. Drain the coolant into a clean
before disassembling it from the engine. Check the container if the coolant is to be reused.
engine coolant pump shaft bearing for abnormal Otherwise, properly dispose of the coolant.
noise, sticking, excessive play and water leakage.
Replace the coolant pump if any of these 2. Remove the radiator cap (Figure 8-4, (1)).
conditions are present. 3. Remove the drain plug or open the drain cock
(Figure 8-4, (2)) at the lower portion of the
CAUTION radiator and drain the coolant.

Pinch Hazard!
Carefully rotate the alternator
1
toward the cylinder block while
loosening the V-belt. Failure to
comply may result in minor or
moderate injury. FULL

LOW

NOTICE
If the engine coolant pump must be replaced,
replace the engine coolant pump as an assembly
only. Do not attempt to repair the engine coolant
pump or replace individual components.
2 K0000074A

NOTICE
Figure 8-4
Make sure the engine and engine coolant are not
hot.

8-6 86E-7 – 98E-7 Series

Engine Coolant Pump COOLING SYSTEM
4. Drain the coolant from the engine block.
• On models equipped with an oil cooler, remove
the coolant hose (Figure 8-5, (1)) at the oil
cooler. 2 1

3
1 K0000163B

Figure 8-7

043935-00X00
7. Disconnect the coolant hoses and the
temperature switch lead wire from the engine
Figure 8-5 coolant pump.
8. Remove the engine coolant pump
• On models not equipped with an oil cooler,
(Figure 8-7, (4)). Discard the gasket.
remove the coolant drain plug (Figure 8-6, (1))
from the engine block. Disassembly of Engine Coolant
Pump
1. Remove the thermostat cover (Figure 8-8, (1)).
Discard the gasket.

1
1
4 2
3
043936-00X00

Figure 8-6
5. Loosen the alternator mounting bolts. Loosen
and remove the V-belt and rotate the alternator
away from the engine and out of the way.
6. Remove the engine coolant fan guard (if
equipped), engine coolant fan (Figure 8-7, (1)),
spacer (Figure 8-7, (2)) and engine coolant
pump V-pulley (Figure 8-7, (3)).
K0000267AX

Figure 8-8
2. Remove the thermostat (Figure 8-8, (2)).
Discard the O-ring. Remove the temperature
switch (Figure 8-8, (3)) and gasket
(Figure 8-8, (4)). Discard the gasket.

86E-7 – 98E-7 Series 8-7

COOLING SYSTEM Engine Coolant Pump

Cleaning and Inspection ■ Water temperature sensor

1. Inspect the water temperature sensor to make
■ Temperature switch sure that it is properly operating. As shown in
1. Check for proper operation of the temperature the following figure, connect an electric resistor
switch. Connect a continuity light or ohmmeter to the coupler of the water temperature sensor
to the temperature switch. Connect one lead to (Figure 8-10, (1)).
the terminal of the switch (Figure 8-9, (1)) and
the other lead to the metal portion of the switch
(Figure 8-9, (2)).
1
3 1
2

K0000576AX

Figure 8-9
2. Place the temperature switch and an accurate Figure 8-10
thermometer (Figure 8-9, (3)) in engine
coolant. 2. Dip the water temperature sensor and an
accurate thermometer (Figure 8-10, (2)) into
3. Slowly increase temperature of the fluid using the cooling water.
an external heat source.
3. Measure the electric resistance value while
4. The temperature switch is operating properly if slowly raising the cooling water temperature
the continuity light or ohmmeter indicates using an external heat source.
continuity when the fluid temperature reaches
225 °F - 235 °F (107 °C - 113 °C). 4. The resistance value at each of the following
temperatures is within the permissible range
specified, the water temperature sensor is
correctly operating.

Cooling water temperature

Resistance (k)
(°C)
20 2.45 +0.14
-0.13

80 0.318 ± 0.008
100 (0.1836)

8-8 86E-7 – 98E-7 Series

Engine Coolant Pump COOLING SYSTEM
■ Thermostat Reassembly of Engine Coolant Pump
1. Check for proper operation of the thermostat. 1. Reinstall the thermostat (Figure 8-13, (1)) and
Place the thermostat (Figure 8-11, (1)) and an a new O-ring.
accurate thermometer (Figure 8-11, (2)) in
warm water.

2 2

5 1

1
4
3

K0000578A

Figure 8-11
2. Slowly increase the temperature of the water
using an external heat source.
3. The thermostat is operating properly if it starts
to open at the temperature value stamped on K0001623AX

the flange of the thermostat, and fully opens as

the temperature of the water is increased. Figure 8-13
2. Reinstall the thermostat cover
■ Radiator cap (Figure 8-13, (2)) and a new gasket. Tighten
1. Check for proper operation of the radiator cap. the thermostat cover bolts.
Install the radiator cap (Figure 8-12, (1)) on a 3. Reinstall the temperature switch
cooling system tester. (Figure 8-13, (3)) and a new gasket
(Figure 8-13, (4)).

1 K0000579A

Figure 8-12
2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05
kgf/cm²) to the radiator cap. The radiator cap
relief valve must open within the specified
range.

86E-7 – 98E-7 Series 8-9

COOLING SYSTEM Engine Coolant Pump

Installation of Engine Coolant Pump

1. Position the engine coolant pump on the engine
and install a new gasket. Install a new special
O-ring (Figure 8-13, (5)) on assembly between
the engine coolant pump and the joint. 2
1
NOTICE
Use a new special O-ring between the engine
K0000584
coolant pump and the joint. Be sure to use the
special O-ring for each engine model. Although Figure 8-15
the O-ring dimensions are the same as a
commercially available O-ring, the material is 6. Reinstall the V-belt. Tighten the V-belt to the
different. proper tension. See Operation & Maintenance
Manual.
7. Reinstall and tighten the drain plug or close the
2. Reinstall the engine coolant pump bolts. drain cock in the radiator. Reinstall and tighten
Tighten the bolts. the engine block drain plug or reconnect the
3. Inspect and reinstall the coolant hoses and the coolant hose at the oil cooler.
temperature switch lead wire. 8. Fill the radiator and engine with engine coolant.
4. Reinstall the engine coolant pump V-pulley See Operation & Maintenance Manual.
(Figure 8-14, (1)), spacer (Figure 8-14, (2))
engine coolant fan (Figure 8-14, (3)) and NOTICE
engine coolant fan guard (if equipped).
• Only use the engine coolant specified by
Komatsu. Other engine coolants may affect
warranty coverage, cause an internal buildup
of rust and scale and/or shorten engine life.
2 3 • Prevent dirt and debris from contaminating
the engine coolant. Carefully clean the
radiator cap and the surrounding area before
you remove the cap.
• Never mix different types of engine coolants.
This may adversely affect the properties of
the engine coolant.

1
K0000163C

Figure 8-14
5. Inspect the condition of the V-belt. There must
be clearance (Figure 8-15, (1)) between the
V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 8-15, (2))
between the V-belt and the bottom of the pulley
groove, replace the V-belt.

8-10 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 9

LUBRICATION
SYSTEM
Page
Before You Begin Servicing ................................................................... 9-3
Introduction............................................................................................. 9-3
Oil Pump Service Information................................................................. 9-4
Lubrication System Diagram .................................................................. 9-6
Checking Engine Oil Pressure ............................................................... 9-7
Oil Pump Components ........................................................................... 9-7
3D88E-7, S3D86E-7, 4D88E-7, S4D86E-7...................................... 9-7
Disassembly of Oil Pump ................................................................. 9-7
Cleaning and Inspection................................................................... 9-8
Reassembly of Oil Pump.................................................................. 9-9
4D98E-7, S4D98E-7 (Trochoid Oil Pump) ..................................... 9-10
Disassembly of Oil Pump ............................................................... 9-10
Cleaning and Inspection................................................................. 9-11
Reassembly of Oil Pump................................................................ 9-12

86E-7 – 98E-7 Series 9-1

LUBRICATION SYSTEM

9-2 86E-7 – 98E-7 Series

Before You Begin Servicing LUBRICATION SYSTEM

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.

INTRODUCTION
This section describes the procedures necessary to
service the 3D88E-7 to S4D86E-7 and 4D98E-7/
S4D98E-7 Trochoid oil pumps.
See Operation & Maintenance Manual for engine
oil and engine oil filter replacement procedures.

86E-7 – 98E-7 Series 9-3

LUBRICATION SYSTEM Oil Pump Service Information

OIL PUMP SERVICE INFORMATION

■ Engine oil pressure

At rated engine RPM

Model 1500 - 1800 2000 - 2500 2600 2700 2800 2900 - 3000 At low idle speed
min-1 min-1 min-1 min-1 min-1 min-1
0.29 - 0.44 MPa 0.34 - 0.49 MPa 0.39 - 0.54 MPa
3D88E-7
(3.0 - 4.5 kgf/cm2) (3.5 - 5.0 kgf/cm2) (4.0 - 5.5 kgf/cm2)
0.29 - 0.44 MPa 0.32 - 0.47 MPa
4D88E-7
(3.0 - 4.5 kgf/cm2) (3.3 - 4.8 kgf/cm2)
0.06 MPa
0.29 - 0.44 MPa 0.34 - 0.49 MPa 0.39 - 0.54 MPa
S3D86E-7 (0.6 kgf/cm2)
(3.0 - 4.5 kgf/cm2) (3.5 - 5.0 kgf/cm2) (4.0 - 5.5 kgf/cm2)
or greater
0.29 - 0.44 MPa 0.36 - 0.51 MPa
S4D86E-7
(3.0 - 4.5 kgf/cm2) (3.7 - 5.2 kgf/cm2)
4D98E-7, 0.29 - 0.39 MPa
S4D98E-7 (3.0 - 4.0 kgf/cm2)

■ Outer rotor outside clearance

Reference
Model Standard Limit
page
Check outer
3D88E-7, S3D86E-7, 0.0035 - 0.0059 in. 0.0098 in. rotor outside
4D88E-7, S4D86E-7 (0.09 - 0.15 mm) (0.25 mm) clearance on
page 9-8
Check outer
0.0039 - 0.0061 in. 0.0098 in. rotor outside
4D98E-7, S4D98E-7
(0.100 - 0.155 mm) (0.25 mm) clearance on
page 9-11

■ Outer rotor side clearance

Model Standard Limit Reference page

3D88E-7, S3D86E-7, 0.0020 - 0.0035 in. 0.0059 in. Check outer rotor side
4D88E-7, S4D86E-7 (0.05 - 0.09 mm) (0.15 mm) clearance on page 9-9
Check outer rotor side
0.0020 - 0.0039 in. 0.0059 in.
4D98E-7, S4D98E-7 clearance on
(0.05 - 0.10 mm) (0.15 mm)
page 9-11

■ Outer rotor to inner rotor tip clearance

Model Standard Limit Reference page

Outer rotor to inner
3D88E-7, S3D86E-7, 0.0063 in.
– rotor tip clearance on
4D88E-7, S4D86E-7 (0.16 mm)
page 9-8
Outer rotor to inner
0.0063 in.
4D98E-7, S4D98E-7 – rotor tip clearance on
(0.16 mm)
page 9-11

9-4 86E-7 – 98E-7 Series

Oil Pump Service Information LUBRICATION SYSTEM
■ Rotor shaft clearance

Reference
Model Inspection item Standard Limit
page
0.3945 - 0.3952 in. 0.3962 in.
Plate bearing I.D.
3D88E-7, (10.020 - 10.038 mm) (10.063 mm) Check rotor
S3D86E-7, 0.3928 - 0.3932 in. 0.3922 in. shaft
Rotor shaft O.D.
4D88E-7, (9.978 - 9.987 mm) (9.963 mm) clearance on
S4D86E-7 0.0013 - 0.0024 in. 0.0039 in. page 9-9
Rotor clearance
(0.033 - 0.060 mm) (0.100 mm)
0.5110 - 0.5126 in. 0.5138 in.
Gear case bearing I.D.
(12.980 - 13.020 mm) (13.050 mm) Check rotor
4D98E-7, 0.5100 - 0.5104 in. 0.5096 in. shaft
Rotor shaft O.D.
S4D98E-7 (12.955 - 12.965 mm) (12.945 mm) clearance on
0.0006 - 0.0026 in. 0.0041 in. page 9-12
Rotor clearance
(0.015 - 0.065 mm) (0.105 mm)

86E-7 – 98E-7 Series 9-5

LUBRICATION SYSTEM Lubrication System Diagram

LUBRICATION SYSTEM DIAGRAM

Oil filter
Turbocharger*
Bypass valve

Oil cooler* Fuel

injection pump

Oil pressure
switch

Cylinder body - main gallery

Pressure
regulator valve
Idle gear Camshaft Crank
Oil pump shaft bearing journal

Piston cooling Rocker arm

Oil suction pipe Crank pin
nozzles* bearing
strainer

Rocker arm

Tappet
cam face

Oil pan
K0000042E

Figure 9-1

Note: Items marked* are not standard equipment on all models.

9-6 86E-7 – 98E-7 Series

Checking Engine Oil Pressure LUBRICATION SYSTEM

CHECKING ENGINE OIL OIL PUMP COMPONENTS

PRESSURE 3D88E-7, S3D86E-7, 4D88E-7,
Perform an engine oil pressure check if there is any S4D86E-7
indication of low oil pressure such as the oil
pressure indicator is on or the oil pressure gauge The oil pump on these model engines is located in
indicates low oil pressure. See Engine oil pressure the front gear case and is driven by the same gear
on page 9-4. train that drives the camshaft and fuel injection
pump. You must remove the front gear case cover
1. Disconnect the wire lead from the oil pressure to gain access to the oil pump.
switch or sending unit (Figure 9-2, (1)).

3 7 1 2 6

5 4

043933-00X00

Figure 9-2 1 – Body

2 – Shaft
2. Remove the oil pressure switch.
3 – Inner rotor
3. Install a mechanical oil pressure gauge in the 4 – Outer rotor
oil pressure switch port. 5 – Cover
6 – Drive gear
4. Start the engine:
7 – Pressure regulator valve
• If the mechanical oil pressure test gauge
indicates good oil pressure, replace the faulty Figure 9-3
oil pressure switch or sending unit, or faulty
machine oil pressure gauge in instrument
Disassembly of Oil Pump
panel.
NOTICE
• If the mechanical oil pressure test gauge
indicates low oil pressure, troubleshoot the If the oil pump must be replaced, replace it as an
lubrication system to locate the cause of the assembly only. Do not replace individual
low oil pressure. See Failure Diagnostic List on components.
Section 17. Repair as necessary.
1. Remove the cooling water fan guard (if
equipped), cooling fan (Figure 9-4, (3)), spacer
(Figure 9-4, (2)), cooling water pump V-pulley
(Figure 9-4, (1)), and V-belt.

86E-7 – 98E-7 Series 9-7

LUBRICATION SYSTEM Oil Pump Components

Cleaning and Inspection

Clean the lubricating oil pump, pressure regulator
valve (Figure 9-3, (7)), and rotor inserting portion.
2 3 Check the parts for wear or flaw. Replace the parts
with new ones as needed.

NOTICE
• Never overfill the engine with engine oil.
• Always keep the oil level between the upper and
lower lines on the oil cap/dipstick.

1
K0000163C

■ Check outer rotor outside clearance

Figure 9-4 Inspect the outside diameter clearance of the outer
2. Remove the crank shaft pulley and gear case rotor. To inspect this, insert a feeler gauge between
cover. See Removal of timing gear case cover the outer rotor (Figure 9-6, (1)) and the lubricating
on page 6-46. oil pump body (Figure 9-6, (2)).
3. Remove the lubricating oil pump assembly
mounting bolts. Remove the lubricating oil
pump assembly (Figure 9-5, (1)) from the gear 1
case flange (Figure 9-5, (2)).
4. You can remove by hand the lubricating oil
pump cover (Figure 9-3, (5)) and outer rotor
(Figure 9-3, (4)).

Figure 9-6
Record the measurement(s) and see Outer rotor
outside clearance on page 9-4 for the service limits.

2
■ Outer rotor to inner rotor tip clearance
Inspect the tip clearance between the outer and
inner rotors. To inspect this, insert a feeler gauge
between the inner rotor tooth tip (Figure 9-7, (1))
1 and the outer rotor tooth tip (Figure 9-7, (2)), and
043934-00X00 measure the clearance.

Figure 9-5

9-8 86E-7 – 98E-7 Series

Oil Pump Components LUBRICATION SYSTEM
■ Check rotor shaft clearance
Inspect the rotor shaft clearance. Measure the
outside diameter of the rotor shaft (Figure 9-9, (1))
and the inside diameter of the cover.
1
Determine the clearance by subtracting the outside
diameter of the rotor from the inside diameter of the
cover.

2
Figure 9-7
Figure 9-9
Record the measurement(s) and see Outer rotor to
inner rotor tip clearance on page 9-4 for the service Record the measurement(s) and see Rotor shaft
limits. clearance on page 9-5 for the service limits.

■ Check outer rotor side clearance Reassembly of Oil Pump

Inspect the side clearance between the lubricating 1. Apply clean lubricating oil to the lubricating oil
oil pump body and the outer rotor. To measure the pump body and inner rotor assembly as well as
side clearance, use a straight edge and feeler to the outer rotor.
gauge (as shown in Figure 9-8) or a depth
2. Insert the outer rotor into the lubricating oil
micrometer.
pump body and inner rotor assembly and install
the cover.
3. Replace the packing with new one.
4. Install the lubricating oil pump assembly to the
gear case by tightening the bolts with the
specified torque.
5. Install the gear case cover. For more
information, see Installation of gear case cover
on page 6-67.
6. Install the crank shaft pulley.
7. Install the cooling water pump V-pulley
(Figure 9-10, (1)), spacer (Figure 9-10, (2)),
cooling water fan (Figure 9-10, (3)), and fan
guard (if equipped).

Figure 9-8
Record the measurement(s) and see Outer rotor
outside clearance on page 9-4 for the service limits.

86E-7 – 98E-7 Series 9-9

LUBRICATION SYSTEM Oil Pump Components

Disassembly of Oil Pump

NOTICE
2 3 If the oil pump must be replaced, replace it as an
assembly only. Do not replace individual
components.

Remove the engine cooling fan guard (if equipped),

engine cooling fan (Figure 9-12, (3)), spacer
(Figure 9-12, (2)), engine coolant pump V-pulley
(Figure 9-12, (1)) and V-belt.
1
K0000163C

Figure 9-10
8. Install the V-belt. Adjust the belt to uniform 2 3
tensile strength in accordance with the
instructions given in Operation & Maintenance
Manual.

4D98E-7, S4D98E-7
(Trochoid Oil Pump)
The oil pump on these model engines is located in
the front gear case and is driven by the same gear
1
train that drives the camshaft and fuel injection K0000163C

pump. You must remove the front gear case cover

to gain access to the oil pump. Figure 9-12
1. Remove the crankshaft pulley and the gear
case cover. See Removal of timing gear case
1 cover on page 6-46.
2 2. Remove the oil pump assembly bolts. Remove
the oil pump assembly (Figure 9-13, (1)) from
5 the gear case housing (Figure 9-13, (2)).

4 K0000043A

1 – Gear case housing

2 – Outer rotor 1
3 – Inner rotor
4 – Cover plate
5 – Drive gear
Figure 9-11 2 K0000049D

Figure 9-13

9-10 86E-7 – 98E-7 Series

Oil Pump Components LUBRICATION SYSTEM
Cleaning and Inspection
Wash the oil pump, oil pressure regulator and oil
1
pump cavity. Inspect for wear or damage. Replace 2
as necessary.

NOTICE
If any oil pump component clearance exceeds its
limit, the oil pump must be replaced as an
assembly. K0001153A

Figure 9-15

■ Check outer rotor outside clearance Record the measurement(s) and see Outer rotor to
inner rotor tip clearance on page 9-4 for the service
Determine the outside clearance of the outer rotor.
limits.
Insert a feeler gauge between the outer rotor
(Figure 9-14, (1)) and gear case oil pump cavity ■ Check outer rotor side clearance
(Figure 9-14, (2)).
Determine the side clearance of the outer rotor
across the pump cavity. Measure the depression
1 using a depth micrometer (Figure 9-16, (1)).
2

K0000045A

Figure 9-14
Record the measurement(s) and see Outer rotor
outside clearance on page 9-4 for the service limits.

■ Outer rotor to inner rotor tip clearance

K0001615A
Determine the outer rotor to inner rotor tip
clearance. Insert a feeler gauge between the top of Figure 9-16
an inner rotor tooth (Figure 9-15, (1)) and the top
of an outer rotor tooth (Figure 9-15, (2)) and Record the measurement(s) and see Outer rotor
measure the clearance. side clearance on page 9-4 for the service limits.

86E-7 – 98E-7 Series 9-11

LUBRICATION SYSTEM Oil Pump Components

■ Check rotor shaft clearance

Determine the rotor shaft clearance. Measure the
outside diameter of the rotor shaft
(Figure 9-17, (1)) and the bore diameter in the gear
case housing (Figure 9-17, (2)).
Calculate the difference between the two
measurements to determine the clearance. 1

1
2 K0000049D

Figure 9-19
4. Reinstall the gear case cover and crankshaft
pulley. See Installation of gear case cover on
page 6-67.
2 5. Reinstall the engine coolant pump V-pulley
K0000047A
(Figure 9-20, (1)), spacer (Figure 9-20, (2)),
Figure 9-17 engine cooling fan (Figure 9-20, (3)) and
engine cooling fan guard (if equipped).
Record the measurement(s) and see Rotor shaft
clearance on page 9-5 for the service limits.

Reassembly of Oil Pump

1. Lubricate the outer rotor and pump bore in the 2 3
gear case with clean engine oil.
2. Reinstall the outer rotor in the gear case
housing. The punch mark (Figure 9-18, (1)) on
the end of the outer rotor must face away from
the gear case housing (Figure 9-18, (2)).

1
K0000163C

Figure 9-20
6. Reinstall the V-belt. Tighten the V-belt to the
proper tension as described in Operation &
1 Maintenance Manual.
K0000048A

Figure 9-18
3. Reinstall the oil pump assembly
(Figure 9-19, (1)) into the gear case housing
(Figure 9-19, (2)). Tighten the bolts to specified
torque.

9-12 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 10

TURBOCHARGER
Page
Before You Begin Servicing ................................................................. 10-3
Introduction........................................................................................... 10-4
Specifications ....................................................................................... 10-4
Turbocharger Service Information.................................................. 10-4
Troubleshooting.................................................................................... 10-5
Turbocharger Components .................................................................. 10-7
Turbocharger Component Functions.................................................... 10-8
Theory of Operation ....................................................................... 10-9
Compressor Side Sealing Mechanism ........................................... 10-9
Waste Gate Modulation.................................................................. 10-9
Washing Procedure............................................................................ 10-10
Periodic Inspection ............................................................................. 10-11
Visual Inspection .......................................................................... 10-11
Inspection of Rotor Rotation......................................................... 10-11
Inspection of Rotor Play ............................................................... 10-11
Removal of Turbocharger............................................................. 10-11
Checking Rotor Play..................................................................... 10-12
Waste Gate Valve Test ................................................................ 10-13
Waste Gate Actuator Leak Test ................................................... 10-13
Installation of Turbocharger.......................................................... 10-13

86E-7 – 98E-7 Series 10-1

TURBOCHARGER

10-2 86E-7 – 98E-7 Series

Before You Begin Servicing TURBOCHARGER

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.

86E-7 – 98E-7 Series 10-3

TURBOCHARGER Introduction

INTRODUCTION
This section describes the servicing of the RHF3, RHF4 and RHF5 model turbochargers.

SPECIFICATIONS
Turbocharger Service Information
Applicable engine model (application) S3D86E-7 S4D86E-7 S4D98E-7
Turbocharger model RHF3 RHF4 RHF5
Turbocharger specification Standard (w/waste gate)
Turbine type Radial flow
Blower (compressor) type Centrifugal
Lubrication External lubrication
Maximum continuous allowable speed 250,000 190,000 180,000
Maximum continuous allowable gas inlet
750 °F (399 °C)
temperature
5.4 lb 5.7 lb 10.3 lb
Weight (Dry)
(24 N; 2.4 kgf) (25 N; 2.6 kgf) (46 N; 4.7 kgf)
Note: VM application is provided with the waste gate.

10-4 86E-7 – 98E-7 Series

Troubleshooting TURBOCHARGER

TROUBLESHOOTING
The following troubleshooting procedures apply to problems identified as turbocharger related. Consider all
other troubleshooting possibilities before cleaning or removing the turbocharger.

■ Excessive exhaust smoke

Cause Corrective action
Clogged air cleaner element Clean or replace the air cleaner element
Blocked air intake port Correct the condition
Leak from a joint in intake line Correct the condition

Cause Corrective action

Compressor impeller dirty Wash the impeller blades.
Deposit of impurities in oil sticking on the turbine side seal Repair the turbocharger. Send to a qualified repair
portion to make turbine revolution heavy facility.
Sticking bearing:
• Insufficient lubrication or clogged lubrication piping • Repair turbocharger. Send to qualified repair facility.
• Excessively high oil temperature • Inspect the lubricating oil line for problem. Correct the
condition and replace lubricating oil.
• Unbalanced rotating part • Repair the turbocharger. Send to a qualified repair
facility.
• Insufficient warming up or sudden stop from loaded • Improper operation of the machine. Refer to the
operation (no-load operation) Operation & Maintenance Manual.
Contact or breakdown of turbine wheel or blower vane:
• Excessive revolution • Inspection and repair of each engine part
• Excessive exhaust temperature rise • Inspection and repair of each engine part
• Foreign matter within turbocharger • Clean the air cleaner and engine compartment. Repair
the turbocharger. Send to a qualified repair facility.
• Worn bearing • Repair the turbocharger. Send to a qualified repair
facility.
• Incorrect assembly of turbocharger • Repair the turbocharger. Send to a qualified repair
facility.

Cause Corrective action

Exhaust system gas leak prior to the turbocharger. Inspect the exhaust system for leaks. Correct the
Condition will decrease turbocharger revolutions. condition.
Deformed or clogged exhaust pipe. Condition will Correct the condition.
decrease turbocharger revolutions.

86E-7 – 98E-7 Series 10-5

TURBOCHARGER Troubleshooting

■ Generates white smoke

Cause Corrective action
Clogged or deformed oil return pipe causing oil flow to the Correct the condition.
blower on the turbine side
Excessive bearing wear causing abnormal wear or Repair the turbocharger. Send to a qualified repair
damage of the seal ring facility.

■ Sudden oil decrease

Cause Corrective action
Excessive bearing wear causing abnormal wear or Repair turbocharger. Send to qualified repair facility.
damage of the seal ring

■ Decrease in output
Cause Corrective action
Gas leak from any part in exhaust piping Correct the condition.
Air leak from discharge side of blower Correct the condition.
Clogged air cleaner element Clean or replace the air cleaner element.
Damaged turbocharger Repair the turbocharger. Send to a qualified repair facility.

■ Poor (slow) response (starting) of turbocharger

Cause Corrective action
Hard carbon deposit on the turbine side (wheel sealing Repair the turbocharger. Send to a qualified repair facility.
portion) causing abnormal revolution of the turbine shaft
Incomplete combustion Correct the condition.

■ Abnormal sound or vibration

Cause Corrective action
Excessively narrowed gas path due to clogged nozzle in Repair the turbocharger. Send to a qualified repair facility.
the turbine wheel chamber or reverse flow of blower
discharge in acceleration (generally called surging)
Contact rotating part Repair the turbocharger. Send to a qualified repair facility.

Cause Corrective action

Loosened intake, exhaust or oil pipe connection with the Correct the condition.
turbocharger
Damaged bearing, contact between rotating part and Repair the turbocharger. Send to a qualified repair facility.
adjacent part, or chipping of the turbine wheel or blower
vane due to foreign matter within the turbocharger
Unbalanced rotating part Repair the turbocharger. Send to a qualified repair facility.

10-6 86E-7 – 98E-7 Series

Turbocharger Components TURBOCHARGER

TURBOCHARGER COMPONENTS
Note: The following illustration is provided for informational purposes only. Komatsu does not offer
individual service parts for turbochargers. If the turbocharger is worn or damaged, it should be
replaced or repaired by a qualified repair facility.

12
15
14 8 7
13 9
4
5
11 3 22
2 23
20 21
28
10 29
24
27
6
19
1 29

14
13
17

18 26

16 32
25 31 30
K0000078A

1 – Turbine shaft 17 – Bolt

2 – Thrust bearing 18 – Lock plate
3 – Oil thrower 19 – Bearing housing
4 – Seal ring 20 – Retaining ring
5 – Seal ring 21 – Bolt
6 – Seal ring (Turbine side) 22 – Bolt
7 – Lock nut 23 – Lock washer
8 – Impeller 24 – Heat protector
9 – Seal plate 25 – Liquid gasket
10 – Journal bearing 26 – Waste gate actuator
11 – Thrust bearing 27 – Hose
12 – Compressor housing 28 – Adapter
13 – Flanged bolt 29 – Clip
14 – Spring washer 30 – Retaining ring
15 – Clamp 31 – Waste gate valve
16 – Turbine housing 32 – Link plate
Figure 10-1

86E-7 – 98E-7 Series 10-7

TURBOCHARGER Turbocharger Component Functions

TURBOCHARGER COMPONENT FUNCTIONS

1 2 3 4 5 6 7 8

20 19 18 17 16 15 14 13 12 11 10 9
037891-00X00

1 – Turbine side clamp 11 – Oil thrower

2 – Lock washer 12 – Compressor housing
3 – M6 hex bolt 13 – Seal plate
4 – Bearing housing 14 – Thrust bearing
5 – M5 hex bolt 15 – Retaining ring
6 – M5 spring washer 16 – Journal bearing
7 – Compressor side clamp 17 – Turbine side seal ring
8 – M3 countersunk flat-head bolt 18 – Heat protector
9 – Shaft end nut 19 – Shaft end nut
10 – Compressor wheel 20 – Turbine shaft

A. Exhaust gas inlet D. Air outlet

B. Exhaust gas outlet E. Oil inlet
C. Air inlet F. Oil outlet
Figure 10-2

10-8 86E-7 – 98E-7 Series

Turbocharger Component Functions TURBOCHARGER
Theory of Operation ■ Bearings
Normally aspirated engines produce horsepower Thrust bearing
that is limited by the atmospheric pressure of the A thrust force is continuously imposed on the
induction air. The turbocharger is an exhaust gas turbine shaft during engine operation. A thrust
pressure driven device that adds to the bearing prevents the shaft from moving laterally
atmospheric pressure, resulting in a boost in under this thrust force.
pressure at the combustion chambers. This
substantially increases the amount of fuel that can Radial bearing
be injected into the combustion chambers, while A floating radial bearing moves with the turbine
maintaining the proper fuel-to-air ratio. A slight shaft as oil films form on the inside and outside
parasitic loss is imposed on the engine because of bearing surfaces. The bearing slipping speed is
added back pressure in the exhaust system. That slower than the turbine shaft speed, resulting in
loss is offset by horsepower gains. The net result is higher dynamic stability and reduced mechanical
substantially increased overall horsepower over noise.
normally aspirated engines.
Lubrication
The turbocharger consists of two main
components: The oil pump delivers oil from the engine to the
turbocharger for cooling and lubrication of the
• Turbine bearings. As oil leaves the turbocharger, it is
returned to the engine.
• Compressor
Compressor Side Sealing Mechanism
■ Turbine
A seal ring and a seal plate form a double wall
The turbine is driven by exhaust gas pressure from
structure at the rear of the compressor impeller.
the engine and is coupled to a shaft on the
The seal ring and seal plate prevent intake air and
compressor side of the turbocharger.
oil leakage.
Exhaust gas velocity is accelerated at the nozzle
portion in the turbine housing where the Waste Gate Modulation
cross-sectional area is reduced. As exhaust passes Excessive boost pressure that cannot be
over the turbine impeller at high linear velocity, the accommodated by the engine can damage the
turbine shaft is rotated at proportionally high rpm. turbocharger. The waste gate is a component that
monitors intake boost pressure on the compressor
■ Compressor side and diverts exhaust gases around the
The compressor is driven by a shaft on the turbine turbocharger turbine. The amount of exhaust gas
side of the turbocharger and increases the diverted is varied to limit turbine rpm and maintain
induction air pressure at the intake manifold. the intake pressure equal to, or less than the
specified maximum level. This improves the
The compressor impeller draws induction air into
response to load variation in the low to medium rpm
the turbocharger, compresses it and directs it into
range and minimizes black smoke.
the engine at high pressure.
A seal ring and heat insulating plate thermally ■ Waste gate control
isolate heat energy, at the turbine side, from the A mechanical pressure sensor in the outlet of the
bearings and the induction air, at the compressor compressor side of the turbocharger opens and
side. closes the waste gate to maintain the specified
intake pressure at the intake manifold.

86E-7 – 98E-7 Series 10-9

TURBOCHARGER Washing Procedure

WASHING PROCEDURE
Note: Inspection, cleaning and repair of the
internal turbocharger components must be
performed by a qualified repair facility.
The washing procedure described in this section is
intended to clean the impeller on the compressor
only if the engine loses rpm, seems sluggish or has
insufficient boost pressure. The process does not
require disassembling any portion of the
turbocharger.
Since washing is quick and easy, perform this
procedure before considering replacement.
1. Start the engine and allow it to reach the normal
operating temperature.
K0000860

NOTICE
Figure 10-3
Avoid damage to the turbocharger or the engine.
Do not spray blower wash fluid or water too 3. Continue to operate the engine under the same
quickly. load for three to four minutes.
Use short strokes from a spray bottle to inject 4. While the engine is still operating at normal load
blower wash fluid or water into the turbocharger. (75 - 80 % of maximum), slowly and evenly
spray 2 - 3 oz (60 - 90 cc) of clean water over a
Spraying too much wash fluid or water, or period of ten to fifteen seconds into the air inlet.
spraying too quickly will damage the
5. Continue to operate the engine under the same
turbocharger.
load for at least ten minutes to completely dry
the air intake system and turbocharger.
2. While the engine is operating at normal load (75 6. Test the engine performance. If engine
- 80 % of maximum), slowly and evenly spray 2 performance has not improved, repeat steps 2
- 3 oz (60 - 90 cc) of blower wash fluid over a through 6. If the engine performance does not
period of ten to fifteen seconds into the air inlet improve after executing the washing process
(Figure 10-3). three times, replace the turbocharger or have it
repaired by a qualified repair facility.

10-10 86E-7 – 98E-7 Series

Periodic Inspection TURBOCHARGER

PERIODIC INSPECTION
Inspect the turbocharger at regularly scheduled Inspection of Rotor Play
intervals (for reference).
To inspect the rotor, the turbocharger must be
Visual Inspection removed. Inspect for maximum rotor end play and
run-out limits before reinstalling.
1. Check for indications of oil leaks at the oil inlet
and outlet lines. Repair or replace the oil lines Removal of Turbocharger
as needed.
1. Shut down the engine and allow the
2. Inspect the air inlet connection to the turbocharger to cool. Remove the exhaust
turbocharger’s turbine side for cracks or broken outlet connection from the turbocharger
hardware. Repair or replace the connection as housing.
needed.
2. Remove the air inlet connection from the
3. Inspect the exhaust outlet connection to the turbocharger housing.
turbocharger’s compressor side for cracks or
broken hardware. Repair or replace the NOTICE
connection as needed.
Do not allow any material to fall into the oil lines or
Inspection of Rotor Rotation the oil inlet and outlet ports of the turbocharger.
1. With the engine cool and not operating,
manually rotate the rotor. Smooth rotation is 3. Remove the inlet and outlet oil lines from the
normal. Any catching or resistance to rotation is turbocharger. Plug the lines and ports with tape
an indication of abnormal operation. Replace to prevent contamination. Discard the sealing
the turbocharger or have it repaired by a washers and O-rings. Inspect the oil lines and
qualified repair facility. replace if damaged.
2. Start the engine. 4. Remove the turbocharger mounting nuts from
3. After the engine reaches normal operating the mounting studs. Lift the turbocharger from
temperature, place a stethoscope firmly against the engine and place it on a clean, level
the turbocharger case. working surface.
4. Increase the rpm gradually. A high-pitched 5. Discard the turbocharger exhaust manifold
sound, occurring at intervals of two or three gasket.
seconds, is an indication of abnormal operation.
Replace the turbocharger or have it repaired by
a qualified repair facility.

86E-7 – 98E-7 Series 10-11

TURBOCHARGER Periodic Inspection

Checking Rotor Play

Note: If rotor play measurements are not within specification, replace the turbocharger assembly or have it
repaired by a qualified facility.

in. (mm)
Standard dimension Wear limit
Rotor play
RHF4 RHF5 RHF4 RHF5
0.0010 - 0.0033 0.0011 - 0.0024 0.0035 0.0035
End play
(0.026 - 0.084) (0.03 - 0.06) (0.09) (0.09)
0.0031 - 0.0051 0.0031 - 0.0051 0.0063 0.0067
Run-out
(0.08 - 0.13) (0.08 - 0.13) (0.16) (0.17)

■ To check rotor end play: ■ To check rotor run-out:

1. Set up a dial indicator as shown (Figure 10-4). 1. Set up a dial indicator as shown (Figure 10-5).
2. Manually move the rotor end-to-end while 2. Manually rotate the rotor while observing
observing indicated readings. Replace the indicated limits. Replace the turbocharger if
turbocharger if end play measurements are run-out measurements are outside specified
outside specified limits. See table above. limits. See table above.

1 1

4
2

037892-00X00

Figure 10-4

3 037893-00X00

Figure 10-5

10-12 86E-7 – 98E-7 Series

Periodic Inspection TURBOCHARGER
Waste Gate Valve Test Waste Gate Actuator Leak Test
Before reinstalling the turbocharger, verify the Allow the pressure, 17 psi (0.12 MPa; 1.2 kgf/cm2)
operation of the waste gate valve. Poor waste gate to remain in the circuit for one minute. After one
operation will adversely affect the engine minute, observe the pressure reading.
performance.
• If the pressure reading is equal to or greater than
15.9 psi (0.11 MPa; 1.1 kgf/cm2), the waste gate
WARNING actuator is not leaking and is operating properly.
Never apply over 40 psi (2.8 kgf/cm2) to the
• If the pressure reading is less than 15.9 psi (0.11
waste gate actuator.
MPa; 1.1 kgf/cm2), the waste gate actuator is
leaking. Replace the turbocharger or have it
NOTICE repaired by a qualified repair facility.
If the waste valve does not meet specifications,
replace the turbocharger or have it repaired by a Installation of Turbocharger
qualified repair facility. 1. Pour 2 oz (60 cc) of clean engine oil in the oil
inlet port at the top of the turbocharger. Rotate
the compressor wheel to ensure the shaft
1. Connect a hand-operated air pump to the waste bearings are lubricated.
gate actuator pipe (Figure 10-6, (1)). The pump
should be equipped with a 30 psi (0.21 MPa; 2. Flush the oil lines to ensure that they are free of
containments.
2.21 kgf/cm2) pressure gauge
(Figure 10-6, (2)), and a pressure release 3. Put a new turbocharger exhaust manifold
valve to release any pressure pumped into the gasket in place and reinstall turbocharger on
system. (Similar pumps are used to check for the exhaust manifold.
leaks in marine gear cases.) 4. Apply anti-seize compound to the turbocharger
mounting studs.
5. Reinstall the mounting nuts. Torque the nuts to
the specified torque.
6. Install new sealing washers and O-rings and
reinstall the inlet and outlet oil lines to the
turbocharger.
1
2 NOTICE
Do not allow any material to fall into the oil lines or
the oil inlet and outlet ports of the turbocharger.

7. Reinstall the air inlet connection to the

turbocharger turbine housing.
3 K00001617X 8. Reinstall the exhaust connection to the
turbocharger compressor housing.
Figure 10-6
2. Apply 17 psi (0.12 MPa; 1.2 kgf/cm2) to the
waste gate actuator (Figure 10-6, (3)) circuit.
Observe if the waste gate valve is open fully. If
the waste valve does not open fully, replace the
turbocharger or have it repaired by a qualified
repair facility.

86E-7 – 98E-7 Series 10-13

TURBOCHARGER Periodic Inspection

10-14 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 11

STARTER MOTOR
Page
Before You Begin Servicing ................................................................. 11-3
Introduction........................................................................................... 11-4
Starter Motor Information ..................................................................... 11-4
3D88E-7 to S4D86E-7 - Standard and Optional ............................ 11-4
4D98E-7 and S4D98E-7 - Standard and Optional ......................... 11-4
Starter Motor Specifications ................................................................. 11-5
Starter Motor Troubleshooting.............................................................. 11-6
Starter Motor Components ................................................................... 11-7
Starter Motor ........................................................................................ 11-8
Removal of Starter Motor ............................................................... 11-8
Disassembly of Starter Motor ......................................................... 11-8
Cleaning and Inspection............................................................... 11-10
Reassembly of Starter Motor........................................................ 11-14
Check Pinion Projection Length ................................................... 11-15
No-Load Test................................................................................ 11-16
Installation of Starter Motor .......................................................... 11-17

86E-7 – 98E-7 Series 11-1

STARTER MOTOR

11-2 86E-7 – 98E-7 Series

Before You Begin Servicing STARTER MOTOR

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.

86E-7 – 98E-7 Series 11-3

STARTER MOTOR Introduction

INTRODUCTION
This section covers the servicing of the starter motor. Part No. YM129900-77010 is typical equipment on
4D98E-7 model engines and is used in this section to show the service procedures for a representative
starter motor. For specific part detail, see the Parts Book for the engine you are working on.

STARTER MOTOR INFORMATION

3D88E-7 to S4D86E-7 - Standard and Optional
No load Loaded
Mfg.
Part No. Mfg. Specification Terminal Amperage min-1 Terminal Amperage min-1
Part No. Torque
voltage draw (rpm) voltage draw (rpm)
87 in.-lb
YM129129 228000- DC 12 V-1.6 HP 90 A 280
Denso 11.5 3000 8 (9.81 N·m; 900
-77010 0251 (1.2 kW) maximum maximum
1.0 kgf·m)
117 in.-lb
YM129407 228000- DC 12 V-1.9 HP 90 A 350
Denso 11.5 3000 8.5 (13.2 N·m; 1000
-77010 3732 (1.4 kW) maximum maximum
1.4 kgf·m)
74 in.-lb
YM129608 S114- DC 12 V-1.9 HP 90 A 250
Hitachi 11 2700 8.4 (8.3 N·m; 1000
-77010 817A (1.4 kW) maximum maximum
0.9 kgf·m)
134 in.-lb
YM129242 S114- DC 12 V-2.3 HP 90 A 370
Hitachi 11 2300 8 (15.1 N·m; 880
-77010 883 (1.7 kW) maximum maximum
1.5 kgf·m)
97 in.-lb
YM129136 S13- DC 12 V-3.1 HP 140 A 400
Hitachi 11 4100 7.7 (11.0 N·m; 1400
-77011 332 (2.3 kW) maximum maximum
1.1 kgf·m)

4D98E-7 and S4D98E-7 - Standard and Optional

No load Loaded
Mfg.
Part No. Mfg. Specification Terminal Amperage min -1
Terminal Amperage min-1
Part No. Torque
voltage draw (rpm) voltage draw (rpm)
97 in.-lb
YM129900 DC 12 V-3.1 HP 140 A 400
Hitachi S13-204 11 4100 7.7 (11.0 N·m; 1400
-77010 (2.3 kW) maximum maximum
1.1 kgf·m)
60 in.-lb
YM129940 DC 12 V-4.0 HP 160 A 300
Hitachi S14-102 12 3600 10.85 (6.9 N·m; 2000
-77011 (3.0 kW) maximum maximum
0.7 kgf·m)

11-4 86E-7 – 98E-7 Series

Starter Motor Specifications STARTER MOTOR

STARTER MOTOR SPECIFICATIONS

Part No. YM129900-77010
Nominal output 3.0 HP (2.3 kW)
Weight 12.1 lb (5.5 kg)
Revolution direction (as viewed from pinion) Clockwise
Engagement system Magnetic shift
Terminal voltage/current 11 V/140 A max
No-load
Revolution 4100 min-1 (rpm)
Terminal voltage/current 2.5 V/1050 A maximum
Loaded 18 ft-lb
Torque
(24.5 N·m; 2.5 kgf·m) minimum
Clutch system Overrunning
Pinion projection voltage at 212 °F (100 °C) 8.6 V maximum
Pinion DP or module/number of teeth M3/9
Difference (O-ring, oil seal) Dry (none)
Application Standard
Spring force 7.868 lbf (35 N; 3.6 kgf)
Brush Standard 0.591 in. (15 mm)
Height
Limit 0.354 in. (9 mm)
Magnetic Series coil resistance 0.27 W at 68 °F (20 °C)
switch Shunt coil resistance 0.60 W at 68 °F (20 °C)
Standard 1.437 in. (36.5 mm)
Outside diameter
Limit 1.398 in. (35 mm)
Standard 0.001 in. (0.03 mm)
Commutator Run-out
Limit 0.008 in. (0.2 mm)
Standard 0.020 - 0.031 in. (0.5 - 0.8 mm)
Insulation depth
Limit 0.008 in. (0.2 mm)
Standard 0.001 in. (0.03 mm)
Armature Run-out
Limit 0.008 in. (0.02 mm)
Armature front 6903DDU
Armature rear 608DDU
Bearing type Nominal No.
Pinion front 60004DDU
Pinion rear 6904DDU
Pinion projection length (length L) 0.012 - 0.059 in. (0.3 - 1.5 mm)

86E-7 – 98E-7 Series 11-5

11-6
Is the shift lever at NO Move shift lever to Is battery fully charged NO ‡&KDUJHRUUHSODFHEDWWHU\
NEUTRAL position? NEUTRAL position. and terminals clean? ‡&OHDQWHUPLQDOV

YES
Engine does not start? Inspect wiring up to solenoid switch
Is starter motor solenoid and repair if necessary.
NO ‡.H\VZLWFK
switch actuating sound
STARTER MOTOR

YES heard? ‡6DIHW\UHOD\

‡6ROHQRLGVZLWFKDVVHPEO\
NO NO ‡(OHFWULFDOFRQQHFWLRQV
Does engine crank? Is starter motor operating? YES

YES
‡$GMXVWSLQLRQSURMHFWLRQOHQJWK
‡,QVSHFWVKLIWOHYHUIRUGHIRUPDWLRQ
Pinion and ring gear NO return spring for fatigue and pinion
meshing normal? for sliding.
YES ‡5HSDLUPHVKLQJEHWZHHQSLQLRQDQG
ring gear or replace as needed.
YES
&RQQHFW0WHUPLQDORIVWDUWHU NO ‡,QVSHFWEUXVKDQGUHSODFHLIZRUQ
Pinion roller clutch or motor directly to battery. ‡,IEUXVKHVDUHQRWZRUQUHSODFHDUPDWXUH
reduction gear damaged. Does starter motor operate? assembly.
Inspect and replace.

YES

Solenoid switch assembly  ,IVWDUWHUPRWRUEHFRPHVZHWUHSODFHVROHQRLGVZLWFK

contact defective. Repair assembly even if function is normal.
STARTER MOTOR TROUBLESHOOTING

NO or replace.
(slow revolution) NO
Is revolution normal? Is battery fully charged ‡&KDUJHRUUHSODFHEDWWHU\ If a problem occurs:
and terminals clean? ‡&OHDQWHUPLQDOV Immediately disconnect battery negative terminal.

YES YES

Inspect fuel system. Is the engine oil NO Engine does not stop
Replace engine oil.
viscosity correct? even when key switch is
turned OFF.
YES

Does engine turn when YES Repair or replace 5HSDLURUUHSODFHNH\VZLWFKVWDUWLQJ

starter motor is replaced? starter motor. motor relay or magnetic switch assembly.

Slow Revolution

Inspect condition of engine.

K0000102E
Starter Motor Troubleshooting

86E-7 – 98E-7 Series

Starter Motor Components STARTER MOTOR

STARTER MOTOR COMPONENTS

13
12 14
11
10
9

7
6
5
4
23
3
2
1 15

18

22

21
19

20

17

16 K0000103A

1 – Pinion shaft 13 – Magnetic switch assembly (solenoid)

2 – M4 bolts (3 used) 14 – Cover
3 – Bearing retainer 15 – M6 bolts (2 used)
4 – Pinion clutch assembly 16 – Armature assembly
5 – Return spring 17 – Field coil assembly
6 – Pinion stop 18 – Positive (+) brushes
7 – Retaining ring 19 – Negative (-) brushes
8 – Gear housing 20 – Brush holder assembly
9 – Shift lever 21 – Rear cover
10 – Torsion spring 22 – M5 through bolts (2 used)
11 – Plunger 23 – M4 bolts (2 used)
12 – Dust covers (shims)
Figure 11-1

86E-7 – 98E-7 Series 11-7

STARTER MOTOR Starter Motor

STARTER MOTOR Disassembly of Starter Motor

1. Loosen the M8 nut from the magnetic switch
WARNING (solenoid) assembly (Figure 11-3). Disconnect
Shock Hazard! the wire from the magnetic switch.
• Turn off the battery switch (if
equipped) or disconnect the
negative battery cable before
servicing the electrical system.

• Check the electrical harnesses for cracks,

abrasions, and damaged or corroded
connectors. Always keep the connectors and
terminals clean.
• Failure to comply could result in death or
K0000104
serious injury.
Figure 11-3
Note: While starter motor design varies between 2. Remove the two M4 bolts (Figure 11-4, (1))
models, the basic repair procedures are the securing the rear cover (Figure 11-4, (2)) to the
same. The following procedures are typical brush holder assembly (Figure 11-4, (3)).
and may differ from the stater being
serviced.
7
Removal of Starter Motor
1. Disconnect the battery cables at the battery,
negative (-) cable first. 4

2. Remove the electrical wires from the magnetic

1
switch assembly.
3. Remove the starter mounting bolts
(Figure 11-2, (1)). Remove the starter motor
from the flywheel housing.

1 6 5 3 2 K0000105A

Figure 11-4
3. Remove the two M5 through bolts
(Figure 11-4, (4)). Separate the rear cover
(Figure 11-4, (2)), field coil assembly
(Figure 11-4, (5)) with the armature assembly
(Figure 11-4, (6)) from the gear housing
(Figure 11-4, (7)).
K0002126

Figure 11-2

11-8 86E-7 – 98E-7 Series

Starter Motor STARTER MOTOR
4. Pull the brush springs up using a brush spring
puller. On the negative (-) side, bring the brush 1
spring into contact with the side of the brush for
lifting from the commutator surface. On the
positive (+) side, remove the brush from the
brush holder assembly (Figure 11-5, (1)). 2 4

3 K0000108A

Figure 11-7
8. Disassemble the dust cover (Figure 11-8, (1))
and shift the lever (Figure 11-8, (2)) from the
1 gear housing.
K0000106A

1
Figure 11-5
5. Remove the brush holder assembly
(Figure 11-6, (1)) from the armature assembly
(Figure 11-6, (3)).

2 K0000109A
1
Figure 11-8
9. Remove the three M4 bolts (Figure 11-9, (1))
securing the bearing retainer assembly
(Figure 11-9, (2)) to the gear housing. Remove
the bearing retainer assembly from the gear
housing.
2 3
K0000107A

Figure 11-6 2

6. Pull the armature assembly (Figure 11-6, (3))

out from the field coil assembly
(Figure 11-6, (2)). 3
7. Remove the two M6 bolts (Figure 11-7, (1))
retaining the magnetic switch assembly
(Figure 11-7, (2)) to the gear housing. Remove
the magnetic switch assembly, dust cover(s)
1
(Figure 11-7, (3)) and torsion spring K0000110A

(Figure 11-7, (4)) from the gear housing.

Figure 11-9

86E-7 – 98E-7 Series 11-9

STARTER MOTOR Starter Motor

10. Remove the pinion clutch assembly Cleaning and Inspection

(Figure 11-9, (3)) from the bearing retainer
assembly. ■ Armature
11. Using a flat-blade screwdriver, remove the
Commutator surface inspection
retaining ring (Figure 11-10, (1)) from the shaft
of the pinion. If the commutator surface is rough, polish the
surface with a #500 to #600 emery cloth
(Figure 11-12).
1

K0000111A

Figure 11-10 K0000117

12. Disassemble the pinion stop

Figure 11-12
(Figure 11-11, (3)), return spring
(Figure 11-11, (4)), pinion clutch assembly Measure commutator outside diameter
(Figure 11-11, (1)), and pinion shaft Measure the commutator outside diameter
(Figure 11-11, (5)). (Figure 11-13). Replace the armature if the
measurement is less than the limit.
4
1
5

2
3
K0000112A

Figure 11-11
K0000113

Figure 11-13
See Starter Motor Specifications on page 11-5 for
the service limit.

11-10 86E-7 – 98E-7 Series

Starter Motor STARTER MOTOR
Measure commutator insulation depth Armature coil insulation test
Measure the depth of the insulating material Check for continuity between a commutator
(Figure 11-14, (1)) between commutator segments segment and the shaft or armature using a
(Figure 11-14, (2)). If the depth measures less than multimeter (Figure 11-16). The multimeter should
the limit, use a hacksaw blade (Figure 11-14, (3)) not indicate continuity.
to remove the insulating material until the depth is
within the limit.
A normal commutator condition is indicated in
(Figure 11-14, (4)). An abnormal commutator
condition is indicated in (Figure 11-14, (5)).

K0000115

Figure 11-16
If the multimeter indicates continuity, replace the
1 2 armature.

Measure armature and commutator run-outs

Measure the armature core run-out and the
commutator run-out using a dial indicator
5 4 K0000118
(Figure 11-17). Replace the armature if either of
the measurements is less than the limit.
Figure 11-14
See Starter Motor Specifications on page 11-5 for
the service limit.

Armature coil continuity test

Check for continuity between the commutator
segments using a multimeter (Figure 11-15). The
multimeter should indicate continuity.

K0000116

Figure 11-17
See Starter Motor Specifications on page 11-5 for
the service limit.

K0000114

Figure 11-15
If the multimeter does not indicate continuity,
replace the armature.

86E-7 – 98E-7 Series 11-11

STARTER MOTOR Starter Motor

■ Field coil Measure brush length

Measure the length of the brush (Figure 11-20).
Field coil continuity test
Replace the brush if the length is less than the limit.
Check for continuity between the field coil terminals
using a multimeter (Figure 11-18). The multimeter
should indicate continuity.
If the multimeter does not indicate continuity,
replace the field coil assembly.

K0000121

Figure 11-20
See Starter Motor Specifications on page 11-5 for
the service limit.
K0000119

■ Magnetic switch
Figure 11-18
If the starter motor becomes wet, replace the
Field coil insulation test magnetic switch even if the magnetic switch
Check for continuity between the field coil terminal assembly function is normal.
and the yoke using a multimeter (Figure 11-19).
The multimeter should not indicate continuity. Shunt coil continuity test
Check for continuity between the “S” terminal and
If the multimeter indicates continuity, replace the the switch body using a multimeter (Figure 11-21).
field coil assembly. The multimeter should indicate continuity.
If the multimeter does not indicate continuity,
replace the magnetic switch.

K0000120

Figure 11-19

K0000124

Figure 11-21

11-12 86E-7 – 98E-7 Series

Starter Motor STARTER MOTOR
Series coil continuity test ■ Pinion clutch assembly
Check for continuity between the “S” and “M”
Pinion clutch assembly inspection
terminals using a multimeter (Figure 11-22). The
multimeter should indicate continuity. Manually rotate the pinion clutch assembly in the
drive direction (Figure 11-24). It should rotate
If the multimeter does not indicate continuity, freely in the drive direction and is locked by turning
replace the magnetic switch. it in the opposite direction. Replace the pinion
clutch assembly if the results are different.

K0000127

K0000125

Figure 11-24
Figure 11-22
Slide the pinion clutch assembly on the shaft. It
Coil resistance test should slide smoothly on the shaft (Figure 11-25).
See Starter Motor Specifications on page 11-5 for Rust, too much grease or damage could prevent
the service limit. the pinion clutch from sliding smoothly. If the pinion
clutch assembly does not slide smoothly, clean the
Contact continuity test shaft and pinion clutch assembly or replace the
Depress the plunger at the bottom of the magnetic damaged component.
switch. Check for continuity between the “B” and
“M” terminals using a multimeter (Figure 11-23).
The multimeter should indicate continuity.
If the multimeter does not indicate continuity,
replace the magnetic switch.

K0000128

Figure 11-25

Ball bearing inspection

Rotate each ball bearing while holding the pinion
clutch assembly (Figure 11-26). Replace the ball
bearing if it does not rotate smoothly or has
K0000126 excessive play.

Figure 11-23

86E-7 – 98E-7 Series 11-13

STARTER MOTOR Starter Motor

4. Apply a small amount of high temperature

lithium grease (obtain locally) to the sliding
portions of the shift lever (Figure 11-28, (1)).
Reassemble the torsion spring
(Figure 11-28, (2)), shift lever and dust cover(s)
(Figure 11-28, (3)), plunger (Figure 11-28, (4))
and magnetic switch assembly
(Figure 11-28, (5)).

3
K0000129

Figure 11-26 2
1
Reassembly of Starter Motor
1. Apply the appropriate starter bendix grease
(obtain locally) to the pinion shaft. Reassemble
5
the pinion shaft (Figure 11-27, (5)), pinion
clutch assembly (Figure 11-27, (1)), return
spring (Figure 11-27, (4)) and pinion stop 4
(Figure 11-27, (3)). Reinstall the retaining ring
(Figure 11-27, (2)) in the groove in the pinion K0000268

shaft. Slide the piston stop over the retaining

ring. Figure 11-28
5. Reassemble the magnetic switch assembly to
4 the gear housing. Pry the pinion away from the
1 gear housing to allow installation of the
5 magnetic switch assembly (Figure 11-29).

2
3
K0000112A

Figure 11-27
2. Reinstall the pinion clutch assembly into the
bearing retainer assembly.
3. Reinstall the bearing retainer assembly and K0000131

pinion assembly to the gear housing. Reinstall

and tighten the three M4 bolts. Figure 11-29
6. Secure the magnetic switch assembly to the
gear housing using the two M6 bolts.

11-14 86E-7 – 98E-7 Series

Starter Motor STARTER MOTOR
7. Carefully install the armature assembly 12. Reinstall the two M4 through bolts
(Figure 11-30, (1)) into the field coil assembly (Figure 11-32). Securely tighten the through
(Figure 11-30, (2)). bolts. Reconnect the wire to the magnetic
switch assembly. Tighten the M8 nut. Reinstall
the cover over the connection.
1

2
K0000269

Figure 11-30
8. Position the brush springs in brush holders K0000104

(Figure 11-31). Reinstall the brushes in the

brush holders. Reversing the brushes will Figure 11-32
cause the starter motor to turn backwards.
Check Pinion Projection Length
1. Connect the positive (+) lead from a battery to
the “S” terminal.
2. Connect the negative (-) lead to the “M”
terminal.
3. Lightly pull the pinion away from the gear
housing.
4. Turn the switch ON and measure the pinion
1
moving distance L in the thrust direction
K0000106A (Figure 11-33). Perform this test within 10
seconds. See Starter Motor Specifications on
Figure 11-31 page 11-5 for the service limit.
9. Carefully install the brush holder assembly to
the armature assembly.
10. Reinstall the field coil assembly with the
armature assembly to the gear housing.
11. Reinstall the rear cover to the brush holder
assembly. Securely tighten the two bolts.

K0000132

Figure 11-33

86E-7 – 98E-7 Series 11-15

STARTER MOTOR Starter Motor

5. If the measured L dimension is outside the

standard range, adjust the dust covers to obtain
the standard range. Dust covers 3
(Figure 11-34, (1)) are available in 0.020 in.
6 1
(0.5 mm) and 0.031 in. (0.8 mm) thicknesses.
M 8
2
7
1
5

4 K0002127A

Figure 11-35
3. Connect a wire lead between the mounting
base of the starter motor (Figure 11-35, (4))
and the battery negative terminal
K0000133 (Figure 11-35, (5)).
4. Connect a voltmeter (Figure 11-35, (7)) to the
Figure 11-34
battery negative (-) terminal (Figure 11-35, (5))
No-Load Test and the main positive (+) battery terminal
(Figure 11-35, (3)) on the starter motor.
Test the characteristics of the starter motor by
5. Install a switch (Figure 11-35, (6)) in a circuit
performing a no-load test.
between the battery positive (+) terminal
(Figure 11-35, (2)) and the starter magnetic
NOTICE switch (solenoid) terminal (Figure 11-35, (8))
The starter motor can be damaged if operated on the starter motor.
continuously longer than 10 seconds while 6. Use a suitable tachometer to monitor the rpm of
performing the no-load test. the starter.
7. Turn the switch to the ON position. Monitor the
1. Secure the starting motor in a vise or other rpm, amperage draw and voltage. For test
suitable fixture. specifications, see 3D88E-7 to S4D86E-7 -
Standard and Optional and 4D98E-7 and
2. Connect an ammeter (Figure 11-35, (1)) in S4D98E-7 - Standard and Optional on
series between the battery positive (+) terminal page 11-4 for the appropriate starter motor.
(Figure 11-35, (2)) and the main positive (+)
terminal (Figure 11-35, (3)) on the starter
motor.
Note: The ammeter and all wire leads used in
this test must have a capacity equal to or
greater than the amperage draw
specification for the starter motor being
tested.

11-16 86E-7 – 98E-7 Series

Starter Motor STARTER MOTOR
Installation of Starter Motor
1. Reinstall the starter motor to the flywheel
housing.
2. Reinstall the starter mounting bolts
(Figure 11-36, (1)). Tighten the bolts to
specification. See Tightening Torques for
Standard Bolts and Nuts on page 4-37.

K0002126

Figure 11-36
3. Reconnect the electrical wires to the magnetic
switch assembly (solenoid). Be sure to place
the cover over the battery positive (+) cable
connection.
4. Reconnect the battery cables at the battery.

86E-7 – 98E-7 Series 11-17

STARTER MOTOR Starter Motor

11-18 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 12

ALTERNATOR
Page
Before You Begin Servicing ................................................................. 12-3
Introduction........................................................................................... 12-4
Dynamo and Alternator Information ..................................................... 12-4
3D88E-7 to S4D98E-7 - Standard and Optional Dynamos ............ 12-4
3D88E-7 to S4D98E-7 - Standard and Optional Alternators .......... 12-4
Alternator Specifications....................................................................... 12-5
Dynamo Specifications......................................................................... 12-5
Alternator Troubleshooting ................................................................... 12-6
Alternator Components ........................................................................ 12-7
Alternator Wiring Diagram .................................................................... 12-8
Alternator Standard Output .................................................................. 12-9
Alternator............................................................................................ 12-10
Removal of Alternator................................................................... 12-10
Disassembly of Alternator ............................................................ 12-10
Reassembly of Alternator ............................................................. 12-12
Installation of Alternator................................................................ 12-14
Dynamo Component Location............................................................ 12-15
Dynamo Wiring Diagram .................................................................... 12-16
Operation of Dynamo ......................................................................... 12-16
Dynamo Standard Output................................................................... 12-17
Testing of Dynamo ............................................................................. 12-18
Testing Stator Coil Continuity....................................................... 12-18
Testing Stator Coil Short-to-Ground............................................. 12-18
Testing Dynamo Regulated Output .............................................. 12-18
Dynamo .............................................................................................. 12-18
Removal of Dynamo..................................................................... 12-18

86E-7 – 98E-7 Series 12-1

ALTERNATOR
Disassembly of Dynamo ...............................................................12-19
Reassembly of Dynamo ................................................................12-19
Installation of Dynamo...................................................................12-20

12-2 86E-7 – 98E-7 Series

Before You Begin Servicing ALTERNATOR

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.

86E-7 – 98E-7 Series 12-3

ALTERNATOR Introduction

INTRODUCTION
This section describes the servicing of the dynamos and alternators. Part No. YM129423-77200 alternator is
used in this section to show the service procedures for the representative alternator. Part No. YM171301-
77201 dynamo is used in this section to show the service procedures for the representative dynamo. For
specific part detail, see the Parts Book for the engine you are working on.

DYNAMO AND ALTERNATOR INFORMATION

3D88E-7 to S4D98E-7 - Standard and Optional Dynamos
Part No. Mfg. Mfg. Part No. Specification
YM171301-77201 Kokusan GP8138 DC 12 V - 15 A
YM119910-77200 Kokusan GP9191 DC 12 V - 20 A

3D88E-7 to S4D98E-7 - Standard and Optional Alternators

Part No. Mfg. Mfg. Part No. Specification
YM119620-77201 Denso 100211-4531 DC 12 V - 40 A
YM129423-77200 Denso 101211-1170 DC 12 V - 40 A with pulse
YM129961-77200 Denso 101211-2591 DC 12 V - 55 A
YM119626-77210 Denso 101211-2951 DC 12 V - 55 A with pulse

12-4 86E-7 – 98E-7 Series

Alternator Specifications ALTERNATOR

ALTERNATOR SPECIFICATIONS
Part No. YM129423-77200
Nominal output (13.5 volts heat) 40 A
Weight 6.17 lb (2.8 kg)
Revolution direction (as viewed from pulley) Clockwise
Rating Continuous
Battery voltage 12 V
Rated revolution 5000 min-1 (rpm)
Operating range 1350 - 18000 min-1 (rpm)
Grounding characteristics Negative (-) side of circuit
Integrated regulator IC regulator
Outside diameter of pulley 2.724 in. (69.2 mm)
Belt shape Type A

DYNAMO SPECIFICATIONS
Part No. YM119910-77200
Nominal output 20 A
Weight 3.97 lb (1.8 kg)
Revolution direction (as viewed from pulley) Clockwise
Rating Continuous
Battery voltage 12 V
Rated revolution 3500 min-1 (rpm)
Operating range 1400 - 6600 min-1 (rpm)
Grounding characteristics Negative (-) side of circuit
Current limiter
Regulator
(Part No. YM119653-77710)
A-belt 2.56 in. (65 mm)
Outside diameter of pulley
Special M-belt 2.28 in. (58 mm)
Belt shape Type A or type special M

86E-7 – 98E-7 Series 12-5

12-6
Turn key switch ON. OFF Disconnect harness L terminal Ground drive machine side OFF
Does battery indicator and IG terminal at alternator L terminal. Does battery Replace the battery indicator.
turn ON? indicator turn on?
ALTERNATOR

ON ON Inspect rotor assembly and

brushes.
Start Engine.

Inspect or replace V-belt.

Battery indicator ON. Inspect alternator.

At idle, does battery Battery indicator flashes. Inspect diode positive (+) side.
indicator turn OFF?

Battery indicator
OFF is dim.
Increase engine speed to
1500 rpm. Turn light switch ON.
ALTERNATOR TROUBLESHOOTING

Battery voltage minus

L terminal voltage is Excessive voltage drop between
greater than 0.5 volt. BAT and batt ( + side) terminal.
Does battery indicator Battery indicator With engine idling,
come ON? is dim. measure voltage at L
terminal and at battery.
Battery voltage minus Check condition of L terminal.
L terminal voltage is Inspect diode negative (-) side.
OFF less than 0.5 volt.
With engine running at 1500
rpm, measure voltage at Battery voltage greater
than 15.5 volts. Replace regulator.
battery.

Battery voltage
is between 13 With engine idling, Does battery indicator ON Inspect auxiliary diode.
and 15 volts. turn light switch ON. come ON?

OFF
Notes: Not abnormal.
1. Use a fully charged battery
2. DC voltmeter: 0 to 30 V, 0.5 class
3. The check method is also applicable to the bench test
Alternator Troubleshooting

86E-7 – 98E-7 Series

Alternator Components ALTERNATOR

ALTERNATOR COMPONENTS
Part No. YM129423-77200 alternator is used in this section to show the service procedures for the
representative alternator. For specific part detail, see the Parts Book for the engine you are working on.

14
12 13
10 11

8 9
6
5
29
4

3 7 19
2
16 18
1 17
25
15 28
27
26
24
23
22
21
20 K0000255

1 – Nut 16 – Nut
2 – Pulley 17 – Insulation bushing
3 – Collar 18 – Spring (2 used)
4 – Front frame housing 19 – Brush holder
5 – Stator assembly 20 – Rear frame housing
6 – Stud (2 used) 21 – Bolt (2 used)
7 – Front frame housing bearing 22 – Holder
8 – Bearing cover 23 – IC regulator assembly
9 – Bearing cover bolt (4 used) 24 – Bolt (2 used)
10 – Rotor assembly 25 – Bolt
11 – Rear frame housing bearing 26 – Brush (2 used)
12 – Bearing cover 27 – Bolt
13 – Thrust washer 28 – Rear cover
14 – Thrust washer 29 – Bolt (3 used)
15 – Nut (2 used)
Figure 12-1

86E-7 – 98E-7 Series 12-7

ALTERNATOR Alternator Wiring Diagram

ALTERNATOR WIRING DIAGRAM

IG 1
IG P
B

PI P L
2
F
IC
L
3 3
0.5PF

B
4A
E T

5 6

1 – Key switch 4 – Battery

2 – Charge lamp (3.4 watts maximum) 5 – Alternator assembly
3 – Load 6 – IC regulator assembly
Figure 12-2

NOTICE NOTICE
Do not short-circuit the charging system between Do not remove the positive (+) battery cable from
alternator terminals IG and L. Damage to the alternator terminal B while the engine is operating.
alternator will result. Damage to the alternator will result.

NOTICE
Do not connect a load between alternator terminals
L and E. Damage to the alternator will result.

12-8 86E-7 – 98E-7 Series

Alternator Standard Output ALTERNATOR

ALTERNATOR STANDARD OUTPUT

Output current
60

Cold
50

temperature at 77 °F (25 °C)

13.5 V, constant ambient
Hot
40

30

20

10

0 1 2 3 4 5 6 7 8
-1
Alternator speed (× 10³ min )

Figure 12-3

86E-7 – 98E-7 Series 12-9

ALTERNATOR Alternator

ALTERNATOR 4. Remove the nut (Figure 12-4, (2)) from the

gear case stud. Remove the alternator.
WARNING
Shock Hazard!
• Turn off the battery switch (if
equipped) or disconnect the
negative battery cable before
servicing the electrical system.

• Check the electrical harnesses for cracks, 2 1

K0000264
abrasions, and damaged or corroded
connectors. Always keep the connectors and
Figure 12-4
terminals clean.
• Failure to comply could result in death or Disassembly of Alternator
serious injury. 1. Remove the nut (Figure 12-5, (1)) from the
shaft of the rotor assembly. Remove the pulley
(Figure 12-5, (2)).
Removal of Alternator
CAUTION
Pinch Hazard!
Carefully rotate the alternator
toward the cylinder block while
loosening the V-belt. Failure to
comply may result in minor or
moderate injury.

1. Disconnect the electrical wires from the

alternator.
2
2. Loosen the V-belt. 1 K0000256

3. Remove the V-belt adjuster from the alternator Figure 12-5

bolt (Figure 12-4, (1)).

12-10 86E-7 – 98E-7 Series

Alternator ALTERNATOR
2. Remove the three bolts (Figure 12-6, (1)) 6. Remove the nut (Figure 12-7, (3)) retaining the
retaining the rear cover (Figure 12-6, (2)) to the insulation bushing (Figure 12-7, (4)). Remove
rear frame assembly. the insulation bushing.
7. Remove the two bolts (Figure 12-8, (1)) and
two nuts (Figure 12-8, (2)) securing the rear
frame housing to the front frame housing.
3 1
2

4 2 1
5

K0000257A

Figure 12-6 K0000265A

3. Remove the brush holder (Figure 12-6, (3)). Figure 12-8

Remove the brush springs (Figure 12-6, (4))
8. Using a press, remove the rotor assembly
and brushes (Figure 12-6, (5)).
(Figure 12-9, (1)) from the front frame housing
4. Remove the bolt retaining the regulator (Figure 12-9, (2)) and rear frame housing
assembly (Figure 12-7, (1)) to the holder (Figure 12-9, (3)).
(Figure 12-7, (2)).
3
3
1 1
4
2

2
K100266A

Figure 12-9
K0000258A

Figure 12-7
5. Remove the bolts retaining the holder
(Figure 12-7, (2)) to the rear frame housing.
Remove the holder.

86E-7 – 98E-7 Series 12-11

ALTERNATOR Alternator

9. Remove the stator assembly

(Figure 12-10, (1)) from the front frame
housing.

3
3 2
1

K0000260A
1
Figure 12-11

K0000259A
Reassembly of Alternator
1. If removed, reinstall the two trust washers
Figure 12-10 (Figure 12-12, (3)) and bearing cover
10. If it is necessary to replace the bearing (Figure 12-12, (2)) in the rear frame housing.
(Figure 12-10, (2)) in the front frame housing, Lubricate the outside diameter of a new bearing
remove the four bolts (Figure 12-10, (3)) (Figure 12-12, (1)). Press the bearing into the
securing the plate (Figure 12-10, (4)) to the rear frame housing.
front frame housing. Remove the plate. Use a
puller to remove the bearing. Discard the
bearing.
11. If it is necessary to replace the bearing
(Figure 12-11, (1)) in the rear frame housing,
use a puller to remove. Discard the bearing.
Remove the bearing cover (Figure 12-11, (2)) 3
and two thrust washers (Figure 12-11, (3)). 2
1

K0000260A

Figure 12-12

12-12 86E-7 – 98E-7 Series

Alternator ALTERNATOR
2. If removed, lubricate the outside diameter of a 5. Align the front frame housing with the rear
new front frame housing bearing. Press the frame housing. Reinstall the two bolts
bearing (Figure 12-13, (2)) into the front frame (Figure 12-15, (1)) and two nuts
housing. Reinstall the plate (Figure 12-13, (4)) (Figure 12-15, (2)).
to the front housing. Tighten the four bolts
(Figure 12-13, (3)). 2

3 1

K0000265A

1
Figure 12-15
6. Reinstall the insulation bushing
K0000259A (Figure 12-16, (4)) and nut (Figure 12-16, (3)).

Figure 12-13 3
3. Position the stator assembly (Figure 12-13, (1)) 1
4
on the front frame housing studs.
4. Lubricate the shaft of the rotor assembly
(Figure 12-14, (1)). Press the rotor assembly
into the front frame housing (Figure 12-14, (2))
and rear frame housing (Figure 12-14, (3)).

3
2
1

2 K0000258A

Figure 12-16
7. Reassemble the regulator assembly
(Figure 12-16, (1)) to the holder
(Figure 12-16, (2)).

K100266A

Figure 12-14

86E-7 – 98E-7 Series 12-13

ALTERNATOR Alternator

8. Reinstall the brush holder (Figure 12-17, (3)), Installation of Alternator

springs (Figure 12-17, (4)) and brushes
(Figure 12-17, (5)). 1. Position the alternator on the gear case.
Loosely reinstall the nut (Figure 12-19, (2)) on
9. Reattach the regulator assembly and holder to the gear case stud and the V-belt adjuster bolt
the rear frame housing. (Figure 12-19, (1)).

3 1

4 2 2 1
K0000264

5
Figure 12-19
2. Reconnect the electrical wires to the alternator.
K0000257A
Tighten the nuts to 15 - 20 in.-lb (1.7 - 2.3 N·m;
17 - 23 kgf·m).
Figure 12-17
3. Reinstall the V-belt. Tighten the V-belt to the
10. Reinstall the rear cover (Figure 12-17, (2)) to proper tension as described in Operation &
the rear frame housing with three bolts Maintenance Manual.
(Figure 12-17, (1)). 4. Start the engine. Listen for any unusual sounds
11. Reassemble the pulley (Figure 12-18, (2)) and from the alternator.
nut (Figure 12-18, (1)) to the shaft of the rotor
assembly. Tighten the nut. NOTICE
Do not operate the engine if the alternator is
producing unusual sounds. Damage to the
alternator will result.

2
1 K0000256

Figure 12-18

12-14 86E-7 – 98E-7 Series

Dynamo Component Location ALTERNATOR

DYNAMO COMPONENT LOCATION

Part No. YM171301-77201 dynamo is used in this section to show the service procedures for the
representative dynamo. For specific part detail, see the Parts Book for the engine you are working on.

2
3
4
7

5
8 9

6 10

11 12

13

14

K0002140X

1 – Rear cover 8 – Spacer

2 – Nut 9 – Stator assembly
3 – Lock washer 10 – Front bearing (2 used)
4 – Flat washer 11 – Flat washer
5 – Rear bearing 12 – Flywheel assembly
6 – Output wire and connector 13 – Pulley half
7 – Plate 14 – Through bolt
Figure 12-20

86E-7 – 98E-7 Series 12-15

ALTERNATOR Dynamo Wiring Diagram

DYNAMO WIRING DIAGRAM

5 6

4
2

K0002137X

1 – Dynamo 4 – Charge lamp (3.4 watts maximum)

2 – Current limiter 5 – Battery
3 – Key switch 6 – Load
Figure 12-21

OPERATION OF DYNAMO
The dynamo consists of a series of permanent magnets that rotate around a stationary stator coil. The
magnets are attached to the flywheel which is rotated via the engine cooling fan drive belt. The resultant
output is an AC (alternating current) signal. The AC is converted to DC (direct current) by the current
limiter. The current limiter outputs charging DC current to the battery.

12-16 86E-7 – 98E-7 Series

Dynamo Standard Output ALTERNATOR

DYNAMO STANDARD OUTPUT

Standard characteristics (12 V)

25

20
Output current (A)

15

10

0
1 2 3 4 5 6 7 × 103

Alternator speed (min-1) K0002138E

Figure 12-22

86E-7 – 98E-7 Series 12-17

ALTERNATOR Testing of Dynamo

TESTING OF DYNAMO DYNAMO

Use a circuit tester or multimeter to perform the
following tests.
Removal of Dynamo

Testing Stator Coil Continuity CAUTION

1. Disconnect the dynamo output wire connector. Pinch Hazard!
2. Connect one meter lead to each of the stator Carefully rotate the alternator
wire terminals and read the meter. toward the cylinder block while
loosening the V-belt. Failure to
Results: The meter reading should indicate comply may result in minor or
continuity. If continuity is not indicated, the windings moderate injury.
are open and the stator must be replaced.

Testing Stator Coil Short-to-Ground 1. Disconnect the output wire connector from the
1. Disconnect the dynamo output wire connector. dynamo.
2. Test continuity between each stator wire 2. Loosen the V-belt.
terminal and engine ground. 3. Remove the V-belt adjuster from the dynamo
Results: The meter reading should infinity. If the bolt (Figure 12-23, (1)).
meter reading indicates continuity, the windings are 4. Remove the nut (Figure 12-23, (2)) from the
shorted to ground and the stator must be replaced. gear case stud. Remove the dynamo.
Testing Dynamo Regulated Output
1. Test and record the battery voltage with the
engine not running.
2. Start the engine and operate it at normal
operating rpm.
3. Again, check the battery voltage with the engine
running.
Results: The meter reading with the engine 1
2 K0002141X
running must be higher than with the engine not
running.
Figure 12-23
• If results are not correct, test the stator for
continuity and shorts to the ground.
• Check the charging system wiring.
• If no problems are found in previous checks,
replace the IC regulator.

12-18 86E-7 – 98E-7 Series

Dynamo ALTERNATOR
Disassembly of Dynamo 4. Remove the screws (Figure 12-26, (1)) and the
stator assembly (Figure 12-26, (2)).
1. Remove the rear cover (Figure 12-24, (1)).
5. Remove the rear bearing (Figure 12-26, (3)).
2. Remove the nut (Figure 12-24, (2)), lock
washer (Figure 12-24, (3)), and flat washer
3
(Figure 12-24, (4)).

1
2
3
4 2

K0002145X

Figure 12-26
K0002143X
Reassembly of Dynamo
Figure 12-24 1. Reinstall the rear bearing (Figure 12-27, (3)).
2. Reinstall the stator (Figure 12-27, (2)) and
3. Remove the through bolt (Figure 12-25, (1)),
screws.
pulley half (Figure 12-25, (2)), flywheel
(Figure 12-25, (3)), flat washer
(Figure 12-25, (4)), bearings 3
(Figure 12-25, (5)), and spacer
(Figure 12-25, (6)).

2
6
1
5
4
3
2 K0002145X

1
Figure 12-27

K0002144X

Figure 12-25

86E-7 – 98E-7 Series 12-19

ALTERNATOR Dynamo

3. Reinstall the front bearings (Figure 12-28, (5)) Installation of Dynamo

and spacer (Figure 12-28, (6)).
1. Position the dynamo on the gear case. Loosely
4. Reinstall the flat washer (Figure 12-28, (4)), reinstall the nut (Figure 12-30, (2)) on the gear
flywheel (Figure 12-28, (3)), pulley half case stud and the V-belt adjuster bolt
(Figure 12-28, (2), and through bolt (Figure 12-30, (1)).
(Figure 12-28, (1)).

6
5
4
3
2 1
2 K0002141X
1

Figure 12-30
2. Reconnect the dynamo output wire connector.
K0002144X
3. Reinstall the V-belt. Tighten the V-belt to the
Figure 12-28 proper tension as described in Operation &
Maintenance Manual.
5. Reinstall the flat washer (Figure 12-29, (4)),
4. Start the engine. Listen for any unusual sounds
lock washer (Figure 12-29, (3)), and nut
from the alternator.
(Figure 12-29, (2)). Tighten the nut to the
specified torque. NOTICE
6. Reinstall the rear cap (Figure 12-29, (1)).
Do not operate the engine if the alternator is
producing unusual sounds. Damage to the
1 alternator will result.
2
3
4

K0002143X

Figure 12-29

12-20 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 13

ELECTRONIC
CONTROL SYSTEM
Page
Before You Begin Servicing ................................................................. 13-3
System Structure.................................................................................. 13-4
Electronic Engine Speed Control ................................................... 13-5
Diesel Particulate Filter (KDPF) ..................................................... 13-7
How to Remove and Reattach the Diesel Particulate Filter (KDPF) .. 13-11
SF and KDPF Maintenance Kit .......................................................... 13-20
Troubleshooting of Electronic Control System ................................... 13-22
Fault Detection Capability ............................................................ 13-22
SMARTASSIST DIRECT (SA-D).................................................. 13-24
Replacement of Components............................................................. 13-25

86E-7 – 98E-7 Series 13-1

ELECTRONIC CONTROL SYSTEM

13-2 86E-7 – 98E-7 Series

Before You Begin Servicing ELECTRONIC CONTROL SYSTEM

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.

86E-7 – 98E-7 Series 13-3

ELECTRONIC CONTROL SYSTEM System Structure

SYSTEM STRUCTURE
This series engines come with the following • Engine speed control schemes
systems: Droop control/Isochronous control/Low-idling
speed up/High-idling speed down/Auto
• Common rail system as shown in the Figure 7-1 deceleration
on page 7-4.
• Starting aid
• Exhaust Gas Recirculation (EGR) system that Auto preheating/After heating
controls the exhaust gas recirculation flow rate
depending on the engine load and speed. • Engine failure detection
• System that controls the Diesel Particulate Filter • CAN communication with the control system of
(KDPF) condition (for clogging), and controls the the driven machine
KDPF regeneration by controlling the intake
throttle. • Diesel Particulate Filter (KDPF) regeneration
control
Figure 13-1 illustrates the outline of the electronic
control system. These functions are described in Main Electronic
Control Components and Features on page 4-7.
Features of the electronic engine control system However components and features vary depending
include: on the driven machine. For details, refer to the
operation manual for these functions.

Fuel feed pump

Supply pump (mechanical) Rail pressure sensor Rail Relief valve

KDOC
Outlet temp.
sensor SF
KDOC Pressure
Inlet temp difference
sensor sensor Main filter

Intake metering
KDOC SF valve

KDPF
Intake Exhaust
EGR-Valve
Re-circulation
Intake throttle
valve
Inj.Nozzle

Liner
Piston
Fuel feed pump
EGR (electromagnetic)
Fuel cooler
Crank speed sensor Injector
Pre-filter

ECU
Gear speed sensor

Accelerator sensor
Fuel tank

Flow of intake
Flow of injection fuel Flow of electrical signal
/return fuel
043932-01E00

Figure 13-1

13-4 86E-7 – 98E-7 Series

System Structure ELECTRONIC CONTROL SYSTEM
Electronic Engine Speed Control Isochronous control
The CL series consists of isochronous design
■ Speed control engines, the speed of which is kept constant from
The electronically controlled engines have no no load to full rated load. See curves (2) in
governor lever. For these engines, the position Figure 13-4 below.
signal of the throttle lever or accelerator pedal of Some VM series engines for general use may be
the driven machine is converted into an electric custom-engineered and have the isochronous
signal by the accelerator sensor (Figure 13-2), capability. Consult the operation manual for
which is then delivered to the fuel injector through application details of such engines.
the ECU (Figure 13-3), allowing the engine speed
to be controlled.

1 2

120 %
110 %
100 %

Torque

30 %

Figure 13-2
800 min-1 60 % 100 %
Engine speed

Figure 13-4

■ Other engine speed control

Low-idling speed up
This feature increases the low-idling speed to some
extent depending on the engine coolant
temperature. When the coolant temperature
044590-00X01
reaches a predetermined value, this feature returns
Figure 13-3 the engine speed to the normal low idle setting,
thus reducing the warm-up time.
■ Engine speed curves
High-idling speed down
Figure 13-4 shows typical engine speed curves The high-idling speed is controlled to 1500 min-1
that outline the relationship between engine speed when starting the engine in cold weather conditions
and load. (-15 °C or below). At least 10 seconds after the
Droop control engine starts, the engine speed returns to the
normal high idle setting by operating the
The VM series engines for general use are
accelerator lever. The engine speed is maintained
designed so that the engine speed is reduced by a
at 1500 min-1 if the accelerator lever is not
certain percentage from 30 % load to full rated
operated, thus preventing the seizures of the
load. See curves (1) in Figure 13-4 below. The
turbocharger. This is a standard feature. However it
same percentage droop is maintained at any no-
depends on the engine model. Refer to the
load speed.
operation manual.

86E-7 – 98E-7 Series 13-5

ELECTRONIC CONTROL SYSTEM System Structure

Auto deceleration (optional)

This feature brings the running engine in low idle
mode automatically when the accelerator pedal is
not operated for a predetermined period of time.
When the pedal is operated, i.e., the accelerator
sensor is activated, the low idle mode is cancelled.
A certain ON/OFF combination of switches (1) - (4)
on the operator’s console (Figure 13-5) will
implement this optional feature. For details, see the
operation manual.

1 2 3 4

Figure 13-5

Others
Other optional features can be provided by
selecting certain ON/OFF combinations of switches
(1) - (4) on the operator’s console (Figure 13-5) will
implement this optional feature. For details, see the
operation manual.

13-6 86E-7 – 98E-7 Series

System Structure ELECTRONIC CONTROL SYSTEM
Diesel Particulate Filter (KDPF)
The KDPF consists of the Diesel Oxidation Catalyst Because ash is a metallic component, it cannot be
(KDOC) and the Soot Filter (SF), held by a case combusted in the KDPF for treatment like the PM.
that sends the exhaust gas to the KDOC and the Therefore, ash is over-accumulated in the SF over
SF. (Figure 13-6) a long period of time. This increases the pressure
The role of the KDPF is to prevent the discharge of loss and has adverse effects on the engine. In this
PM by breaking down the hazardous constituents case, maintenance must be performed to remove
with the KDOC and collecting the PM with the SF. the SF with the accumulated ash from the KDPF.
The PM clogs the SF if left there and the engine Komatsu recommends to do this maintenance once
performance decreases, so a means of every 3,000 operating hours.
regeneration is required. Komatsu engines use a
continuous regeneration method. While continuing Be sure to use the specified fuel and lubricating oil
the operation, the KDPF collects the PM and is so that the KDPF can fulfill its function. For fuel, use
regenerated at the same time. To perform the diesel fuel (ultra-low sulfur) with a sulfur mass of 15
regeneration, the PM collected in the SF is ppm or lower. If you use a fuel other than the
combusted with NO2 generated in the KDOC and specified, performance of the catalyst contained in
O2 in the exhaust gas. At the same time, the KDOC the KDOC deteriorates rapidly due to sulfur.
purifies the exhaust gas elements such as HC and Because of this, the KDPF cannot develop its
CO into H2O and CO2. regeneration capabilities and PM accumulates
easier. This leads to increased fuel consumption
Apart from the PM, ash also collects in the SF. This and a deterioration of general engine receptiveness
comes mostly from metallic components in the caused by decreased engine performance and
additives to the lubricating oil. Part of the lubricating frequent switching to the regeneration mode.
oil is burnt in the high temperature combustion
chamber and exhausted along with the combustion For lubricating oil, use low ash oil. If you use any
gas. In that case, metallic components are other than the specified lubricating oil, a large
collected together with the PM in the SF. However, amount of ash is vented through the exhaust and
because the amount of ash is very little compared the KDPF will clog within a short period of time.
to the PM, it does not clog the SF immediately. This will not only cause the engine output to
decrease and the fuel costs to increase, but also
makes earlier maintenance of the SF necessary.

Outline of Diesel Particulate Filter (KDPF)

Pressure difference
sensor

Silencer portion
Hold mat (Option parts)

Exh. Gas in Exh. gas out

Exh. gas out

Case, SF

SF(soot filter)

Case, KDOC

KDOC
(diesel oxidation catalyst) 044869-00EN00

Figure 13-6

86E-7 – 98E-7 Series 13-7

ELECTRONIC CONTROL SYSTEM System Structure

■ Overview of Diesel Particulate Filter • White smoke may be discharged from the exhaust
(KDPF) regeneration control pipe right after starting a cold engine or during
acceleration.
Electrical components such as the KDPF differential
This is due to discharge of water vapor. When the
pressure sensor, temperature sensor, and intake
exhaust temperature increases, the white smoke
throttle are installed in the KDPF. If the KDPF cannot
disappears. Always perform the KDPF
perform continuous regeneration due to low load
regeneration in a well-ventilated and safe location.
operation, the ECU uses these electrical components
to control assisted KDPF regeneration (KDPF • The exhaust gas is purified through the catalyst
regeneration control) automatically to prevent PM installed in the KDPF, so the smell of the exhaust
from over-accumulating. gas is different from the exhaust gas of a
conventional diesel engine.
■ Self-regeneration (passive regeneration)
Regeneration without the use of regeneration CAUTION
assistance devices (normal)
• During reset regeneration, post-injection is
During the operation at high speed or high load, the used and fuel is burned directly inside the
exhaust temperature rises and PM is continuously KDPF (burned by chemical reaction inside the
combusted and eliminated. KDOC). Through this heat, regeneration
occurs inside the SF, but the combustion
■ Assisted regeneration increases the temperature of the exhaust gas
(passive regeneration) to close to 600 °C (1112 °F). Stay away from
Regeneration with the use of assistance devices the exhaust gas. Extremely hot exhaust gas
(e.g. the intake throttle) may burn you. Be careful that neither people
nor flammable materials are near the exhaust
When the differential pressure in the SF inlet/outlet gas outlet.
in the KDPF rises, the differential pressure sensor
installed to the KDPF detects the increase. The • Post-injection can cause the fuel
ECU commands the intake throttle to open the consumption to increase by a small amount.
throttle according to the detected differential • Through this genuine regeneration method,
pressure to adjust the amount of engine intake air. the dilution of the lubricating oil with fuel
The ECU also controls the regeneration by caused by the post-injection is kept to a
performing after-injection to increase the exhaust minimum, but some dilution is possible for
temperature. At this time, the EGR valve is closed. low-load operation (low temperature exhaust
gas) of fork lifters or similar machines. Make
■ Reset regeneration sure that you do a daily check of the oil level.
(automatic regeneration)
Regeneration with the combined use of assisted
regeneration and post-injection ■ Stationary regeneration
(manual stationary regeneration)
Approximately every 100 hours of operation, the
assisted regeneration and post-injection are Although the KDPF performs the regeneration
automatically used together to control regeneration control, if the operation conditions with idling at no
by increasing the exhaust temperature to burn off load and low speed/low load operation are
and remove PM. frequently repeated, the PM may not be
regenerated.
These automatic regenerations can be performed If the ECU determines that performing the
during operation. No special operation is required stationary regeneration is required at this time, the
for the operator. The following conditions may KDPF regeneration request lamp comes on. If the
occur due to the characteristics of the KDPF KDPF regeneration request lamp comes on,
system, but they are not malfunctions. immediately perform the stationary regeneration by
performing the following operation. If the operation
• The engine sound may change due to the
is continued with the KDPF regeneration request
adjustment of intake throttle valve and degree of
lamp being come on, an excessive amount of PM
opening of the EGR valve when starting and
will accumulate. Abnormal combustion of PM may
completing the KDPF regeneration.
cause fire and damage to the KDPF.

13-8 86E-7 – 98E-7 Series

System Structure ELECTRONIC CONTROL SYSTEM
Operation procedures of stationary ■ Precautions for stationary regeneration
regeneration
• See “METHOD FOR OPERATING TESTING
• See “METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE)” in the
MENU (REGENERATION FOR SERVICE)” in the Shop Manual for chassis.
Shop Manual for chassis.
• Be sure to check the remaining fuel level to avoid
the engine from running out of fuel. (Stationary
regeneration requires sufficient fuel that can run
the engine for at least 1 hour.)
• Make sure that no other failure other than
excessive deposits is observed.

■ Recovery regeneration (optional)

The KDPF can not be regenerated by the reset
regeneration or the stationary regeneration when
the excessive PM is accumulated. Therefore,
optional recovery regeneration function is available.
The recovery regeneration requires longer
regeneration time and lower temperature than that
of the reset regeneration and the stationary
regeneration. However, the function varies
depending on the driven machine. For details, refer
to the operation manual for these functions.

■ Precautions for recovery regeneration

• Do not disconnect SMARTASSIST DIRECT (SA-
D) or the computer while performing the recovery
regeneration. (Check the remaining battery level.
Recovery regeneration takes approximately 4
hours to complete.)
• Be sure to check the remaining fuel level to avoid
the engine from running out of fuel. (Recovery
regeneration requires sufficient fuel that can run
the engine for at least 4 hours.)
• Make sure that no other failure other than
excessive deposits is observed.

86E-7 – 98E-7 Series 13-9

ELECTRONIC CONTROL SYSTEM System Structure

■ KDPF service Exh. gas Pressure

temp sensors difference sensor
KDOC: Maintenance-free parts
Replacement only, every 9000 hrs of
operation. Silencer
Case,KDPF
SF: Parts that require maintenance
If your engine is equipped with KDPF
cleaning alarm, clean the KDPF when the KDOC SF
alarm lamp comes on. If your engine is not
equipped with KDPF cleaning alarm, clean
the KDPF every 6000 hrs of operation.

044159-00EN00

Figure 13-7

Engine Periodic maintenance interval

Item Emission warranty (Useful life)
type Replacement Clean
19 - 37 kW 5000 hrs or 7 years, whichever comes first Every 9000 hrs
KDOC N/A
≥ 37 kW 8000 hrs or 10 years, whichever comes first of operation
19 - 37 kW 5000 hrs or 7 years, whichever comes first With KDPF cleaning alarm: when the alarm
Every 9000 hrs comes on
SF
≥ 37 kW 8000 hrs or 10 years, whichever comes first of operation Without KDPF cleaning alarm: every 6000 hrs
of operation

■ Procedures for servicing the Diesel Particulate Filter (KDPF)

1. SF cleaning
In order to clean the SF, it is necessary to remove it with the case from the KDPF. In principle, the SF
can be removed while the KDPF unit is still mounted to the engine, but depending on how the engine is
mounted in the driven machine, it may be easier to first remove the KDPF assembly and then remove
the SF. Accordingly, select the procedure taking into account the KDPF unit mounting location and how
the engine is mounted.
2. KDOC replacement
Replacement of the KDOC requires replacement of both the catalyst section and case section as a unit,
therefore removal of the KDPF unit is necessary. (In reality, the KDOC is not normally replaced on its
own - instead, the whole KDPF assembly including SF is usually replaced.)

13-10 86E-7 – 98E-7 Series

How to Remove and Reattach the KDPF ELECTRONIC CONTROL SYSTEM

HOW TO REMOVE AND REATTACH THE DIESEL PARTICULATE

FILTER (KDPF)
An overview of the Diesel Particulate Filter (KDPF) KDPF flywheel housing-mounted type
is given in page 13-7, however explanations of 1. Removal of the SF side exhaust pressure hose
components in removal, reattachment, and
• Loosen the hose clip (Figure 13-10, (3)) for
replacement are given in Figure 13-8 and
the hose (Figure 13-10, (2)) connected to the
Figure 13-9. SF side exhaust pressure pipe
Figure 13-8 shows the whole KDPF unit, and (Figure 13-10, (1)), and remove from the pipe.
broadly speaking, the KDPF unit comprises the
2
KDPF assembly and the sensor unit. The sensor
unit contains an exhaust temperature sensor and 3
exhaust differential pressure sensor. 1
Figure 13-9 shows the KDPF assembly by itself
after the sensor unit has been removed, and this
comprises the KDOC, SF, silencer or outlet flange, 4
and stiffener.
057632-00X00

Sensor unit
Exhaust temperature sensor Figure 13-10
Exhaust differential pressure sensor

NOTICE
• SF cleaning is also possible while the exhaust
pressure pipe is attached, therefore it is not
necessary to remove the pipe joint bolts
(Figure 13-10, (4)).
KDPF complete 057648-00EN00
• When replacing the SF, remove the pipe joint
bolts together with the gasket.
Figure 13-8 KDPF unit
2. Removal of the sensor bracket
Stiffener • Loosen the sensor bracket (Figure 13-11, (3))
M8 flange bolts (2 pcs.) (Figure 13-11, (4))
that mount the exhaust differential pressure
sensor (Figure 13-11, (1)) and the exhaust
temperature sensor coupler
KDOC
(Figure 13-11, (2)), and remove.
SF
• Put the removed sensor bracket on the engine
side with the sensor, coupler, hose, harness
Silencer
(or outlet flange)
and other parts connected so that they do not
057666-00EN00
interfere when removing other parts.
Figure 13-9 KDPF assembly
1 2 34
■ How to remove the soot filter (SF)
When cleaning the SF, it is possible to remove the
SF alone without removing the KDPF from the
engine. The KDPF may be mounted either on top of
the flywheel housing or on top of the exhaust
manifold. Some details may differ, so different
procedures are shown below.

057633-00X00

Figure 13-11

86E-7 – 98E-7 Series 13-11

ELECTRONIC CONTROL SYSTEM How to Remove and Reattach the KDPF

3. Removal of the KDPF stay fixing bolts

• Remove the silencer (or outlet flange)
(Figure 13-12, (1)) side KDPF stay
(Figure 13-12, (2)) and the M10 bolts (2 pcs.)
(Figure 13-12, (3)) that affix the flywheel
housing. Leave the stiffener attached to the
KDPF stay.

1
057636-00X00

Figure 13-14
2 5. Removal of the soot filter (SF)
• Remove the M8 bolts and flange nuts
3 (Figure 13-15, (2)) (8 or 10 of each) that fix the
SF (Figure 13-15, (1)). For the parts difficult to
057634-00X00
access with common tools, use joint tools, etc.
Figure 13-12 • Remove the stiffeners (4 pcs.)
(Figure 13-15, (3)), and remove the SF and
4. Removal of the silencer (or outlet flange)
gasket from the KDOC (Figure 13-15, (4)).
• Remove the M8 bolts and flange nuts Put marks on the stiffener before removing to
(Figure 13-13, (2)) (8 or 10 of each) that fix the identify the position and angle so that it can be
silencer (or outlet flange) (Figure 13-13, (1): easily reinstalled.
in this diagram, outlet flange).
• Remove the stiffeners (4 pcs.)
(Figure 13-11, (3)), gasket (1 pc.), and the
silencer (or outlet flange).

4
3
3
2 2
1
1 057637-00X00

Figure 13-15
This completes the removal of the soot filter (SF).
057635-00X00

KDPF exhaust manifold-mounted type

Figure 13-13
In principle, the procedure is the same as for the
flywheel housing-mounted type, but with the
NOTICE exhaust manifold-mounted type, the sensor bracket
Remove the stiffener making note of its position has a stiffener between the KDOC and the SF.
and angle.
1. Removal of the SF side exhaust pressure
hose
• Loosen the hose clip for the hose
(Figure 13-16, (2)) connected to the SF side
exhaust pressure pipe (Figure 13-16, (1)),
and remove from the pipe.

13-12 86E-7 – 98E-7 Series

How to Remove and Reattach the KDPF ELECTRONIC CONTROL SYSTEM

2 1 3 5 6 4

1
4
2 057640-00X00
057638-00X00

Figure 13-18
Figure 13-16
4. Removal of the silencer (or outlet flange)
NOTICE • Remove the M8 bolts and flange nuts
(Figure 13-16, (5)) (8 or 10 of each) that fix the
• SF cleaning is also possible while the exhaust
silencer (or outlet flange) (Figure 13-16, (4)).
pressure pipe is attached, therefore it is not
necessary to remove the pipe joint bolts • Remove the stiffeners (4 pcs.)
(Figure 13-14, (3)). (Figure 13-14, (6)), gasket (1 pc.), and the
silencer (or outlet flange). Put marks on the
• When replacing the SF, remove the pipe joint
stiffener before removing to identify the
bolts together with the gasket.
position and angle so that it can be easily
reinstalled.
2. Removal of the sensor bracket
5. Removal of the soot filter (SF)
• Loosen the sensor bracket (Figure 13-17, (1))
M8 flange bolts (2 pcs.) (Figure 13-17, (2)) • Remove the M8 bolts and flange nuts
that mount the exhaust differential pressure (Figure 13-19, (2)) (8 or 10 of each) that fix the
sensor and the exhaust temperature sensor SF (Figure 13-19, (1)).
coupler, and remove. • Remove the stiffeners (4 pcs.)
• The removed bracket holds the sensor, (Figure 13-19, (3)), and remove the SF and
coupler, hose, harness, and other parts so that gasket from the KDOC (Figure 13-19, (4)).
they do not interfere with the engine when Put marks on the stiffener before removing to
mounted. identify the position and angle so that it can be
easily reinstalled.
2 1
4 3 2 1

057639-00X00
057641-00X00

Figure 13-17
Figure 13-19
3. Removal of the soot filter (SF) fixing bolts
This completes the removal of the soot filter (SF).
• Remove the M10 flange bolts (2 pcs.)
(Figure 13-18, (3)) and the M10 flange nut
(1 pc.) (Figure 13-18, (4)) that fix the SF
stiffener (Figure 13-18, (1)) and KDPF stay
(Figure 13-18, (2)). Depending on the model,
the configuration and fixing method of the
engine-side stay may differ.

86E-7 – 98E-7 Series 13-13

ELECTRONIC CONTROL SYSTEM How to Remove and Reattach the KDPF

■ How to reattach the soot filter (SF) 4. Reattachment of the sensor bracket
• Reattach the sensor bracket that had been
KDPF flywheel housing-mounted type
moved to the engine side to the outlet flange
1. Reassembly of the SF side stiffener (Figure 13-20, (4)). (M8 flange
• For reassembly of the SF after cleaning, bolts (2 pcs.))
reverse the steps for its removal.
Reassemble the SF onto the KDOC. Making 5. Reattachment of the SF side exhaust
note of its position and angle, reattach the pressure hose
stiffener in its original position. (M8 bolts and • Replace the exhaust pressure hose with a new
flange nuts, 8 or 10 of each) one. Insert a new hose into the SF exhaust
• Replace the M8 flange bolts and nuts with new pressure pipe, and tighten the hose clip. As a
ones. guideline, replace the exhaust pressure hose
every 3000 hours.
• Replace the gasket with a new one.
• At the same time, replace the KDOC side
• For the parts difficult to access with common exhaust pressure hose with a new one.
tools, use set wrench or joint tools, etc.
M8 tightening torque 26 ± 5 N·m
2. Reattachment of the silencer (or outlet flange) M10 tightening torque 49 ± 5 N·m
• Install the silencer (or outlet flange), following
the same details as for installation of the SF. KDPF exhaust manifold-mounted type
Making note of its position and angle, reattach Details of reattachment of the SF and silencer (or
the stiffener in its original position. (M8 bolts outlet flange) are the same as for the flywheel
and flange nuts, 8 or 10 of each) housing-mounted type. Reattachment on the KDPF
• Replace the M8 flange bolts and nuts with new stay is different to with the flywheel housing-
ones. mounted type, therefore follow the procedures
• Replace the gasket with a new one. below.

3. Reattachment on the KDPF stay 1. Reattachment on the KDPF stay

• Temporarily fasten the KDPF stay • After reattachment of the SF on the KDOC,
(Figure 13-20, (1)) on the silencer (or outlet reattach the silencer (or outlet flange) to the SF
flange) side to the flywheel housing using M10 using the stiffener. At this time, align the
flange bolts (2 pcs.) (Figure 13-20, (2)). notches on the bottom of the stiffener
(Figure 13-21, (1)) underneath the silencer
• Before fully tightening, slightly loosen the M10 with the stud bolt in the center of the KDPF stay
flange bolts (2 pcs.) (Figure 13-18, (3)) that (Figure 13-21, (2)), and reattach the stiffener
affix the stiffener (Figure 13-18, (4)) and the (M8 bolts and flange nuts, 8 or 10 of each).
KDPF stay, and after fully tightening the KDPF Make note of the position and angle of the
stay and the flywheel housing bolts stiffeners (4 pcs.).
(Figure 13-20, (2)), fully tighten the stiffener
bolts (Figure 13-20, (3)). • Replace the M8 flange bolts and nuts with new
ones.
• Replace the gasket with a new one.
4 • Next, affix the stiffener (Figure 13-21, (1)) and
KDPF stay (Figure 13-21, (2)). (M10 bolts
(2 pcs.), M10 flange nut (1 pc.))
3 • Depending on the model, the configuration and
1 fixing method of the KDPF stay may differ.
3
Repair parts required for reattachment after
2 SF cleaning or replacement are shown on
page 13-20.
057644-00X00

Figure 13-20

13-14 86E-7 – 98E-7 Series

How to Remove and Reattach the KDPF ELECTRONIC CONTROL SYSTEM

057667-00X00

Figure 13-22
2. Removal of the KDPF unit
• Remove the 4 M8 flange nuts
(Figure 13-23, (1)) on the exhaust manifold
flange.
1 • Remove the M10 flange bolts (2 pcs. each,
total 4 pcs.) (Figure 13-23, (2, 3)) that affix the
stays (2 locations) (on the back of the KDPF
housing), that themselves affixes the KDPF.
2
• Remove the KDPF unit together with the
exhaust flange gasket (1 pc.).
• Leave the stiffener attached to the KDPF stay
057650-00X00 on the silencer (or outlet flange).
Figure 13-21

M8 tightening torque 26 ± 5 N·m

1
M10 tightening torque 49 ± 5 N·m

■ How to remove the KDPF unit

4
When replacing the KDPF or the KDOC alone,
removal of the KDPF unit is necessary.
(See page 13-11 for an explanation of the KDPF 3
unit and KDPF assembly)
2 057646-00X00

KDPF flywheel housing-mounted type

Figure 13-23
1. Removal of the sensor and coupler wiring
• Remove the exhaust differential pressure NOTICE
sensor connected to the sensor bracket
(Figure 13-22, (1)) and the wiring from the Do not lift the sensor or wire harness together
engine or driven machine that is connected to with the KDPF. The sensor may break.
the exhaust temperature sensor couplers
(2 pcs.) (Figure 13-22, (2)).

86E-7 – 98E-7 Series 13-15

ELECTRONIC CONTROL SYSTEM How to Remove and Reattach the KDPF

3. Removal of the sensor unit KDPF exhaust manifold-mounted type

When replacing the KDPF assembly, the sensor As with the flywheel housing-mounted type, if
unit is reused, therefore remove this from the replacing the KDPF assembly or the KDOC alone,
KDPF unit. then removal of the KDPF unit is necessary.

• Removal of the exhaust temperature 1. Removal of the sensor and coupler wiring
sensor • Remove the exhaust differential pressure
Loosen the band (Figure 13-24, (1)) that fixes sensor (Figure 13-25, (2)) connected to the
the exhaust harness. From two locations on sensor bracket (Figure 13-25, (1)), and the
the exhaust temperature sensor, remove the wiring (Figure 13-25, (4)) from the engine or
17 mm bolt from one location driven machine that is connected to the
(Figure 13-24, (2)) and the 13 mm bolt from exhaust temperature sensor couplers (2 pcs.)
the other (Figure 13-24, (3)). Leave the (Figure 13-25, (3)).
exhaust temperature sensor couplers (2 pcs.)
(Figure 13-24, (4)) mounted on the sensor 1 2
bracket section.

2 3 1 8 7 4 8

5
3

057649-00X00

6 Figure 13-25

057647-00X00 2. Removal of the KDPF unit

• Remove the fixing bolts (2 pcs.)
Figure 13-24
(Figure 13-26, (2)) and flange nut
• Removal of the exhaust pressure pipe (Figure 13-26, (3)) from the KDPF stay
Remove the M12 pipe joint bolts (2 pcs.) (Figure 13-26, (1)) on the silencer (or outlet
(Figure 13-24, (6)) that affix the exhaust flange) side.
pressure pipe (Figure 13-24, (5)). Leave the
exhaust differential pressure sensor
(Figure 13-24, (7)) mounted on the sensor
bracket section.
• Removal of the sensor bracket 2
Loosen the M8 flange bolts (2 pcs.)
4
(Figure 13-24, (8)) and remove the sensor
bracket. Leave the exhaust differential
pressure sensor and the exhaust temperature 1
sensor coupler attached to the sensor bracket. 3
057651-00X00

This makes the KDPF unit the KDPF assembly,

and replacement is possible. Figure 13-26

If replacing only the KDOC and leaving the SF as • Remove the KDPF stay (Figure 13-27, (1))
is, then remove only the sensor unit connected to fixing bolts (2 pcs.) (Figure 13-27, (2, 3)) on
the KDOC, and leave the sensor bracket fixed to the other side. Stay configuration and numbers
the SF affixed, together with the sensor coupler. of bolts will differ depending on the model, but
Next, remove the M8 bolts and flange nuts (8 or the method for fixing will be largely the same.
10 of each) that affix the SF and KDOC. This • Finally, remove the exhaust manifold flange
enables replacement of the KDOC unit. nuts (4 pcs.) (Figure 13-26, (4)), and remove
the KDPF unit together with the gasket.

13-16 86E-7 – 98E-7 Series

How to Remove and Reattach the KDPF ELECTRONIC CONTROL SYSTEM
■ How to reattach the KDPF
KDPF flywheel housing-mounted type
This procedure shows how to install a new KDPF
2 assembly. In principle, the procedure is the reverse
of that for removal. First, reattach the removed
sensor unit to the KDPF assembly.
3
1 1. Reattachment of the exhaust temperature
sensor
• On two locations on the removed exhaust
057652-00X00
temperature sensor, attach the 17 mm bolt in
one location, and the 13 mm bolt in the other.
Figure 13-27
Tightening torque 40 ± 5 N·m
NOTICE • Tighten the 2 loosened exhaust temperature
Do not lift the sensor or wire harness together sensor harness bands.
with the KDPF. The sensor may break.
2. Reattachment of the exhaust pressure pipe
• Reattach the removed exhaust pressure pipe
3. Removal of the sensor unit (2 pcs.). At this time, replace the pipe joint bolt,
When replacing the KDPF assembly, the sensor the gasket, and the hose with new ones. As a
unit is reused, therefore remove this from the guideline, replace the exhaust pressure hose
KDPF unit. The procedure for removal is that every 3000 hours.
same as for the flywheel housing-mounted type. • When tightening the pipe joint bolt, apply anti-
Refer to page 13-16. seize compound to the threaded sections.
This makes the KDPF unit the KDPF assembly,
M12 pipe joint bolt
and replacement is possible. 29.4 ± 5 N·m
tightening torque
If replacing only the KDOC and leaving the SF as
is, then remove only the sensor unit connected to 3. Reattachment of the sensor bracket
the KDOC, and leave the sensor bracket fixed to • Reattach the removed sensor bracket to the
the SF affixed, together with the sensor coupler. SF stiffener. (M8 flange bolts (2 pcs.))
Next, remove the M8 bolts and flange nuts (8 or
10 of each) that affix the SF and KDOC. This This completes the KDPF unit.
enables replacement of the KDOC unit.
Repair parts required for reinstallation of the
exhaust differential pressure sensor are
shown on page 13-20.

4. Reattachment of the KDPF unit

• First, slightly loosen the flange bolts (2 pcs.)
(Figure 13-28, (2)) that attach the KDPF stay
(Figure 13-28, (1)) and the stiffener so that
these have some play.
• Replace the exhaust manifold flange gasket
with a new one, and attach the KDPF unit to the
exhaust manifold stud bolt.
• Temporarily tighten the KDPF assembly
central stay M10 bolts (2 pcs.)
(Figure 13-28, (3)).

86E-7 – 98E-7 Series 13-17

ELECTRONIC CONTROL SYSTEM How to Remove and Reattach the KDPF

• Seat the exhaust manifold flange KDPF exhaust manifold-mounted type

(Figure 13-28, (4)) using M8 flange nuts If the engine bonnet-mounted type, stay
(4 pcs.), and temporarily tighten. configuration and fixing method will differ
• Fully tighten the central stay M10 bolts depending on the engine model. This explains a
(Figure 13-28, (3)). typical model.
• Fully tighten the flange nuts (4 pcs.) on the 1. Reattachment of the sensor unit
exhaust manifold flange.
• Reattach the removed sensor unit (exhaust
• Fully tighten the M10 flange bolts (2 pcs.) temperature sensor and exhaust differential
(Figure 13-28, (5)) of the KDPF stay on the pressure sensor), and reattach the bracket to
flywheel housing side. the SF stiffener. Up until this point is the same
• Fully tighten the KDPF stay M8 flange bolts as for the flywheel housing-mounted type, so
(2 pcs.) (Figure 13-28, (2)). refer to the details on the previous pages.

Repair parts required for reinstallation of the

exhaust differential pressure sensor are
6 shown on page 13-20.
4

2. Reattachment of the KDPF unit

2
• Replace the exhaust manifold flange gasket
1 with a new one, place the KDPF unit upon this,
2 and temporarily tighten the flange nuts (4 pcs.)
5 (Figure 13-29, (1)).

3 057653-00X00

Figure 13-28

26 ± 5 N·m
M8 tightening torque
(Nut: 16 ± 5 N·m)
M10 tightening torque 49 ± 5 N·m 1

5. Driven machine wiring

• Connect the exhaust pressure sensor to the 057668-00X00

sensor bracket and the wiring from the engine

Figure 13-29
or driven machine to the exhaust temperature
sensor couplers (2 pcs.). • Temporarily tighten the stiffener
(Figure 13-30, (1)) and the KDPF stay
This completes reattachment of the KDPF unit.
(Figure 13-30, (2)) on the silencer (or outlet
If only the KDOC has been replaced, then first flange) side with flange bolts (2 pcs.)
affix the KDOC and SF using M8 bolts and nuts (8 (Figure 13-30, (3)) and a flange nut
or 10 of each), and with the KDPF assembly, (Figure 13-30, (4)) until it is seated.
proceed as above. • Next, fully tighten the flange nuts on the
exhaust manifold flange (4 pcs.)
• Replace the M8 flange bolts and nuts with new
(Figure 13-30, (5)), then fully tighten the
ones.
KDPF stay flange bolts and flange nuts.
• Replace the gasket with a new one.

13-18 86E-7 – 98E-7 Series

How to Remove and Reattach the KDPF ELECTRONIC CONTROL SYSTEM
3. Driven machine wiring
Connect the exhaust differential pressure sensor
to the sensor bracket and the wiring from the
2 engine or driven machine to the exhaust
3 temperature sensor couplers (2 pcs.).
5 This completes reattachment of the KDPF unit.
If only the KDOC has been replaced, then first
1 affix the KDOC and SF using M8 bolts and nuts (8
4 057669-00X00 or 10 of each), and with the KDPF assembly,
proceed as above.
Figure 13-30
• Replace the M8 flange bolts and nuts with new
• Next, affix the KDPF unit to the KDPF stay on ones.
the flywheel housing side. First, slightly loosen
• Replace the gasket with a new one.
the fixing bolts (Figure 13-31, (2)) in two
locations on the KDPF stay (Figure 13-31, (1))
so that these have some play and temporarily
tighten the KDPF unit stay fixing bolts
(Figure 13-31, (4)). Next, temporarily tighten
the KDPF stay fixing bolts (Figure 13-31, (2))
until it seats, then fully tighten the KDPF and
stay fixing bolts (Figure 13-31, (4)). Lastly,
fully tighten the KDPF stay fixing bolts
(Figure 13-31, (2)).

3 057645-00X00

Figure 13-31

26 ± 5 N·m
M8 tightening torque
(Nut: 16 ± 5 N·m)
M10 tightening torque 49 ± 5 N·m

Note: In principle, it is not necessary to loosen

the fixing bolts (Figure 13-31, (3)) that
affix the KDPF stay to the engine,
however adjust according to conditions.

86E-7 – 98E-7 Series 13-19

ELECTRONIC CONTROL SYSTEM

SF AND KDPF MAINTENANCE KIT

The required individual parts are available for SF cleaning and replacement, and for maintenance when
replacing the KDPF assembly and the KDOC, however the kit as below is also available. There are two
types - for the KDPF housing, and for the differential pressure sensor hose, therefore select in accordance
with the engine model and the KDPF installation location.

Engine model name

KDPF installation 3D88E-7 S3D86E-7 4D88E-7
Kit name Part name Part No.
location Exh. M Exh. M Exh. M
Remarks FW side FW side FW side
side side side
YM129930-13201 80 × 80 1 – 1 1 1 –
Gasket
Exhaust YM128300-13230 102 × 102 – 1 – – – 1
gage
flange YM26306-080002 M8 4 – 4 – 4
Flange nut
YM26306-100002 M10 – 4 – 4 – 4
KDOC-SF
mainte- Bolt YM129A00-16610 M8 × 28 16 16 16 16 16 16
nance kit
KDPF Flange nut YM26306-080002 M8 16 16 16 16 16 16
Stiffener YM129A00-16600 – 2 2 2 2 2 2
KDPF
Gasket YM129E00-16600 – – – – – – –
Kit part No. YM129A00-16900 YM129A00-16900 YM129A00-16900
YM129A00-17600 L = 170 1 – – – 1 –
Hose CMP YM129C00-17600 L = 200 – – 1 – – –
(ø13.5) YM129A00-17610 L = 90 – 1 – 1 – 1
YM129C01-17610 L = 105 – – – – – –
Differential
pressure Hose CMP YM129A00-17650 L = 130 1 – 1 – 1 –
sensor (ø9.8)
hose kit YM129A00-17670 L = 90 – 1 – 1 – 1
Pipe joint bolt YM129A00-13350 – 2 2 2 2 2 2
Gasket YM129A00-17311 – 4 4 4 4 4 4
YM129A YM129C YM129C YM129C YM129A YM129C
Kit part No.
00-17900 01-17900 00-17900 01-17900 00-17900 01-17900

Engine model name

KDPF installation S4D86E-7 4D98E-7 S4D98E-7
Kit name Part name Part No.
location Exh. M Exh. M Exh. M
Remarks FW side FW side FW side
side side side
YM129930-13201 80 × 80 1 – 1 – 1 –
Gasket
Exhaust YM128300-13230 102 × 102 – 1 1 – 1
gage
flange YM26306-080002 M8 4 – 4 – 4 –
Flange nut
YM26306-100002 M10 – 4 – 4 – 4
KDOC-SF
mainte- Bolt YM129A00-16610 M8 × 28 20 20 20 20 20 20
nance kit
KDPF Flange nut YM26306-080002 M8 20 20 20 20 20 20
Stiffener YM129A00-16600 – – – – – – –
KDPF
Gasket YM129E00-16600 – 2 2 2 2 2 2
Kit part No. YM129E00-16900 YM129E00-16900 YM129E00-16900
YM129A00-17600 L = 170 – – – – – –
Hose CMP YM129C00-17600 L = 200 1 – 1 – 1 –
(ø13.5) YM129A00-17610 L = 90 – – – 1 – –
YM129C01-17610 L = 105 – 1 – – – 1
Differential
pressure Hose CMP YM129A00-17650 L = 130 1 – 1 – 1 –
sensor (ø9.8)
hose kit YM129A00-17670 L = 90 – 1 – 1 – 1
Pipe joint bolt YM129A00-13350 – 2 2 2 2 2 2
Gasket YM129A00-17311 – 4 4 4 4 4 4
YM129C YM129E YM129C YM129C YM129C YM129E
Kit part No. 00-17900 00-17900 00-17900 01-17900 00-17900 00-17900

13-20 86E-7 – 98E-7 Series

SF and KDPF Maintenance Kit ELECTRONIC CONTROL SYSTEM
The required individual clamps are available when replacing the wire harnesses and other parts. However
the kit as below is also available.

Kit name Kit Part No. Part name Part No. Qty
Band clip YM129A00-91200 25
Band YM129C00-91200 3
Harness clamp Band YM29621-200000 4
YM129A00-91000
service kit Band YM29621-100000 3
Connector crop YM129A00-91430 5
Boots YM129A00-91450 3

86E-7 – 98E-7 Series 13-21

ELECTRONIC CONTROL SYSTEM Troubleshooting of Electronic Control System

TROUBLESHOOTING OF ELECTRONIC CONTROL SYSTEM

How to detect faults on the electronic control
engine equipped with a fault indicator lamp
(optional). 1

WARNING
• Never use the ECU for other purposes than
intended or in other ways than specified by
Komatsu. Doing so could result in the
violation of emission control regulations and
will void the product warranty.
• When replacing the ECU, it is necessary to
transfer the data from the old ECU to the new
ECU using SMARTASSIST DIRECT (SA-D).
Consult your authorized dealer who can
handle SMARTASSIST DIRECT (SA-D). 1 – Fault indicator
If the data is not correctly transfered to the Figure 13-32
new ECU, the engine performance can not be
ensured. Figure 13-32 Typical operator’s console

• Improper use or misuse of the ECU may result

in death or serious injury due to an abrupt
and unexpected increase in engine speed.

Fault Detection Capability

ECU has a fault detection capability that diagnoses
various faults based on the information detected by
the electronic control sensors and other engine
fault detection sensors. Depending on the fault
detected by the sensors, the operation that is
performed when the fault occurs can be set
individually as option. ECU turns on the fault
indicator lamp (optional), and the indicator
indicates that the fault is detected.
The fault indicator lamp comes on for
approximately 2 seconds when the power is
supplied to ECU, then goes off. The flashing
pattern tells you that the power is supplied to ECU.
The fault indicator lamp is located on a panel as
shown in (Figure 13-32, (1)).

NOTICE
Shut down the engine if the fault indicator comes
on. Continuing running the engine with the fault
indicator being on may result in a serious
malfunction of or damage to the engine, and will
void the engine warranty.

13-22 86E-7 – 98E-7 Series

Troubleshooting of Electronic Control System ELECTRONIC CONTROL SYSTEM
Figure 13-33 exemplifies flashing patterns of the fault indicator lamp.
The fault indicator lamp comes on for approximately 2 seconds when the switch is turned on, and goes off
while the engine is running. If a fault occurs in ECU, this indicator lamp will come on 3 seconds after the
indicator lamp goes off, and the lamp continuously stays on. If a fault occurs while the engine is running,
the fault indicator lamp comes on at the time of fault occurrence.

(Normal operation)
Power up
2s

On

Off

(When faults occur)

Power up
2s 3s On
On

Off 054321-00EN00

Figure 13-33

Fail-safe
Fail Safe
Engine kept running
‡Limp-home
Limp Home
for as long as possible
‡Engine
Engine Shut Down
shutdown
Fault
Operator’s console
Fault indicator lamp flashes

CAN SMARTASSIST DIRECT

Diagnostics

Connector USB-CAN
adaptor WindowsPC

Output to other ECU(s)

Figure 13-34

NOTICE
If the fault indicator lamp comes on, stop the engine immediately and contact your authorized dealer.

86E-7 – 98E-7 Series 13-23

ELECTRONIC CONTROL SYSTEM Troubleshooting of Electronic Control System

SMARTASSIST DIRECT (SA-D)

When the ECU or injectors are replaced, you need
to rewrite the individual data inside the ECU.
A special treatment is also necessary when
replacing KDPF or sensors that affects the
electronic control system.
A connector is provided at an end of the machine
harness so that the genuine SMMARTASSIST
DIRECT (SA-D) can be loaded with data from the
ECU. See Figure 13-35 and Figure 13-36.
Contact your authorized dealer or distributor that
can handle SA-D to repair or replace the electronic
control parts. Also, refer to the SMARTASSIST
DIRECT operation manual for the detailed
operation.

SMARTASSIST DIRECT

Windows
PC

USB

CAN
Communication
adaptor

ISO 15765-4

Figure 13-35

DEUTSCH
DTM06-06S-E007

Batt.12V NC

CANH NC

CANL GND

Mating connector (SMARTASSIST DIRECT side)

DEUTSCH
DTM04-06P-E003

Figure 13-36

13-24 86E-7 – 98E-7 Series

Replacement of Components ELECTRONIC CONTROL SYSTEM

REPLACEMENT OF COMPONENTS
If any part for the electronic control system must be repaired or replaced as a result of periodic
maintenance or the failure diagnosis, do not attempt to repair the individual device of the electronic control
system. Refer to the “Troubleshooting” section, and replace the parts or entire assembly.

■ Processing the KDPF regeneration after the parts replacement

The following parts are used for the calculation of the accumulated PM amount. Therefore, when there is a
fault in these parts, the accumulated PM amount may be miscalculated. Be sure to perform the KDPF
regeneration in order to eliminate the calculation error of the accumulated PM amount after replacing parts.

• Injector • Rail CMP or rail pressure sensor

• Supply pump • KDOC
• EGR valve • Intake throttle
• ECU • EGR gas temperature sensor
• EGR pressure sensor • KDPF inlet temperature sensor
• KDPF differential pressure sensor • Intake manifold temperature sensor
• KDPF inside temperature sensor • Fuel temperature sensor
• Exhaust manifold temperature sensor • Crankshaft rotation sensor
• Cooling water temperature sensor

1. Start and warm-up the engine until the cooling water temperature is 60 °C or higher, then let it idle.
2. Without optional recovery regeneration function equipped, perform the stationary regeneration. For
details on regeneration operation, see Operation procedures of stationary regeneration on page 13-9.
3. With optional recovery regeneration function equipped, when the ECU determines that the PM
sediment amount is 12 g/l or more, the recovery regeneration request is displayed. Perform recovery
regeneration. For details on regeneration operation, see Operation procedures of stationary
regeneration on page 13-9.
4. If sediment is 12 g/l or less, then go to the stationary regeneration determination flow.

86E-7 – 98E-7 Series 13-25

ELECTRONIC CONTROL SYSTEM Replacement of Components

Calculation of PM sediment amount in KDPF

ECU calculates the PM sediment amount that is accumulated in soot filter (SF) by following 2 methods:
• Method C calculates the difference between the estimated PM sediment amount that is discharged from
the engine and the estimated PM sediment amount that is burned inside the SF.
• Method P calculates the PM sediment amount accumulated in the SF from the pressure difference
between the inlet and outlet of the SF.
ECU uses the PM sediment amount whichever is greater for regeneration control.

■ Processing after the ECU replacement (when it is impossible to inherit from the old ECU)
When the history data could not be inherited from the old ECU at the time of replacing the ECU, the data for
the accumulated Ash*1 amount is reset, accordingly estimate the PM sediment amount from the
accumulated Ash using method P, and determine if SF cleaning is necessary.
Procedures for when the history data could not be inherited are shown below.
1. After ECU replacement, the procedure for burning PM by using KDPF regeneration (stationary
regeneration or recovery regeneration when optional recovery regeneration function equipped) is the
same as in the previous chapter.
2. Operate the engine at high idling for 10 minutes or more until the situation has stabilized.
3. After operation has completed, check the ash sediment amount. On the monitoring display of service
mode of the machine monitor, confirm the “KDPF Amount of PM (P)” (Code No.: 63800) data. For
operation procedures refer to the Shop Manual for chassis.
4. When the PM sediment amount (P method) exceeds 5 g/l, clean the soot filter (SF).
*1: Refer to page 13-7 for PM and Ash.

13-26 86E-7 – 98E-7 Series

Replacement of Components ELECTRONIC CONTROL SYSTEM
■ Required processing at the CR-related
parts replacement
SA-D operation
Replacement Bosch
parts Processing KDPF
ECU rewrite
regeneration
ECU  *2
Injector  
KDPF  
SF  
KDOC  
Rail  
Supply pump – 
Other* 1
– 

*1: EGR valve, intake throttle, KDPF differential pressure

sensor, KDPF inlet temperature sensor, KDPF inside
temperature sensor, EGR pressure sensor, intake manifold
temperature sensor, EGR gas temperature sensor, exhaust
manifold temperature sensor, crankshaft speed sensor, fuel
temperature sensor, cooling water temperature sensor.
*2: When the history data could not be inherited from the old
ECU, processing the KDPF regeneration is required.
Furthermore, it is required to clean the SF when the
accumulated amount by method P after the KDPF
regeneration exceeds 5 g/l.

86E-7 – 98E-7 Series 13-27

ELECTRONIC CONTROL SYSTEM Replacement of Components

13-28 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 14

ELECTRIC WIRING
Page
Electric Wiring Precautions .................................................................. 14-3
Electrical Wire Resistance.................................................................... 14-4
Battery Cable Resistance..................................................................... 14-5
Electrical Wire Sizes - Voltage Drop .................................................... 14-6
Conversion of AWG to European Standards........................................ 14-7

86E-7 – 98E-7 Series 14-1

ELECTRIC WIRING

14-2 86E-7 – 98E-7 Series

Electric Wiring Precautions ELECTRIC WIRING

ELECTRIC WIRING PRECAUTIONS

Failure to follow these precautions may result in the failure of an electrical component and the loss of
warranty coverage on that item as well as related items. Make sure that all users read and understand
these precautions.

NOTICE NOTICE
Do not reverse the positive (+) and negative (-) Removing the battery cables or the battery while
ends of the battery cable. The alternator diode and the engine is operating may cause damage to the
stator coil will be damaged. current limiter depending on the electrical
equipment being used. This situation could cause
NOTICE loss of control of output voltage. The continuous
high voltage of 23 - 24 V (for 5000 min-1 (rpm)
When the battery indicator goes out, it should not dynamo) will damage the current limiter and other
come on again. The battery indicator only comes electrical equipment.
on during operation if the alternator fails. However,
if an LED is used in the battery indicator, the LED
will shine faintly during normal operation.
NOTICE
Reversing the battery cable connections at the
NOTICE battery or on the engine will destroy the SCR diode
in the current limiter. This will cause the charging
Make sure that the combined total resistance of the system to malfunction and may cause damage to
battery cable in both directions between the starter the electrical harnesses.
motor and the battery is within the value indicated
in the Battery Cable Resistance chart in the Electric
Wiring Section of this manual. The starter motor will
malfunction and fail if the resistance is higher than
the specified value.

86E-7 – 98E-7 Series 14-3

ELECTRIC WIRING Electrical Wire Resistance

ELECTRICAL WIRE RESISTANCE

AWG Metric nominal mm² Ohms/foot resistance
20 0.5 0.009967
18 0.8 0.006340
16 1.25 0.004359
14 2 0.002685
12 3 0.001704
10 5 0.001073
8 8 0.000707
6 15 0.000421
4 20 0.000270
2 30 0.000158
1 40 0.000130
0 (1/0) 50 0.000103
00 (2/0) 60 0.000087
000 (3/0) 85 0.000066
0000 (4/0) 100 0.000051

Wiring voltage drop should not exceed 5 % [0.05] × 12 volts = 0.6 volts.
Voltage drop = Current [Amps] × Length of wire [feet] × Resistance per foot 
Example:
Current draw of 100 Amps × 3 feet of 4 AWG wire
100 Amps × 3 feet × 0.000270 = 0.08 volts [voltage drop]

14-4 86E-7 – 98E-7 Series

Battery Cable Resistance ELECTRIC WIRING

BATTERY CABLE RESISTANCE

Maximum total battery cable length
(positive cable + negative cable + a*)
AWG mm² 12 V starter motor output
Less than 2.68 HP (2 kW) Greater than 2.68 HP (2 kW)
m ft m ft
6 15 1.5 4.75 N/A N/A
4 20 2.3 7.4 N/A N/A
2 30 3.8 12.6 2.3 7.5
1 40 4.6 15.3 2.8 9.2
0 (1/0) 50 5.9 19.5 3.5 11.6
00 (2/0) 60 7.0 22.8 4.2 13.7
000(3/0) 85 9.3 30.5 5.6 18.3
0000 (4/0) 100 11.9 39.0 7.1 23.4
00000 (5/0) 125 N/A N/A 8.3 27.3
000000 (6/0) 150 N/A N/A 10.1 33.3

Note:
• Total allowable resistance of the complete battery cable circuit (positive cable + negative cable + a*)
(a*: Resistance () of a battery switch or other electrical equipment having high resistance).
• For starter motors of less than 2.68 HP (2 kW): the total resistance must be less than 0.002 .
For starter motors of greater than 2.68 HP (2 kW): the total resistance must be less than 0.0012 .

86E-7 – 98E-7 Series 14-5

ELECTRIC WIRING Electrical Wire Sizes - Voltage Drop

ELECTRICAL WIRE SIZES - VOLTAGE DROP

Total Length of conductor from source of current to device and back to source (in feet)
current
on circuit 10 15 20 25 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170
in amps
12 v Wire size (AWG)
5 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6
10 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2
15 12 10 10 8 8 6 6 6 4 4 2 2 2 2 2 1 1 1 1
20 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 2/0
25 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 3/0
30 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 3/0
40 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0 4/0
50 6 6 4 4 2 2 1 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0
60 6 4 4 2 2 1 0 2/0 3/0 3/0 4/0 4/0 4/0
70 6 4 2 2 1 0 2/0 3/0 3/0 4/0 4/0
80 6 4 2 2 1 0 3/0 3/0 4/0 4/0
90 4 2 2 1 0 2/0 3/0 4/0 4/0
100 4 2 2 1 0 2/0 3/0 4/0
24 v
5 18 18 18 16 16 14 12 12 12 10 10 10 10 10 8 8 8 8 8
10 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6
15 16 14 12 12 10 10 8 8 6 6 6 6 6 4 4 4 4 4 2
20 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2
25 12 12 10 10 8 6 6 6 4 4 4 4 2 2 2 2 2 2 1
30 12 10 10 8 8 6 6 4 4 4 2 2 2 2 2 1 1 1 1
40 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 2/0
50 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 3/0
60 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 3/0
70 8 6 6 4 4 2 2 1 1 0 0 2/0 2/0 3/0 3/0 3/0 3/0 4/0 4/0
80 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0 4/0
90 8 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0 4/0 4/0
100 6 6 4 4 2 2 1 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0

14-6 86E-7 – 98E-7 Series

Conversion of AWG to European Standards ELECTRIC WIRING

CONVERSION OF AWG TO EUROPEAN STANDARDS

Conductor size Conductor diameter Conductor cross-sectional area
(AWG) (mm) (mm2)
25 0.455 0.163
24 0.511 0.205
23 0.573 0.259
22 0.644 0.325
21 0.723 0.412
20 0.812 0.519
19 0.992 0.653
18 1.024 0.823
17 1.15 1.04
16 1.29 1.31
15 1.45 1.65
14 1.63 2.08
13 1.83 2.63
12 2.05 3.31
11 2.30 4.15
10 2.59 5.27
9 2.91 6.62
8 3.26 8.35
7 3.67 10.6
6 4.11 13.3
5 4.62 16.8
4 5.19 21.2
3 5.83 26.7
2 6.54 33.6
1 7.35 42.4
0 (1/0) 8.25 53.4
00 (2/0) 9.27 67.5
000(3/0) 10.40 85.0
0000 (4/0) 11.68 107.2
00000 (5/0) 13.12 135.1
000000 (6/0) 14.73 170.3
1.1 circular mil (CM)  0.0005067 mm 2

86E-7 – 98E-7 Series 14-7

ELECTRIC WIRING Conversion of AWG to European Standards

14-8 86E-7 – 98E-7 Series

 TROUBLESHOOTING

86E-7 – 98E-7 Series

 Section 15

FAILURE CODE (DTC)

GENERAL DESCRIPTION
Page
Failure code (DTC) list ......................................................................... 15-7
Description ......................................................................................... 15-14
Sensor related .................................................................................... 15-15
Crank speed sensor ..................................................................... 15-15
#B0336: Crank Signal Error..................................................... 15-15
#B0337: No Crank Signal ........................................................ 15-17
Cam speed sensor ....................................................................... 15-19
#B0341: Cam Signal Error....................................................... 15-19
#B0342: No Cam Signal .......................................................... 15-21
#B1341: Cam Angle Offset Error ............................................. 15-23
#B0008: No Signal on Both Crank and Cam Speed Sensor ... 15-25
Accelerator sensor ....................................................................... 15-26
#B0123: Accelerator Sensor 1 (High voltage) ......................... 15-26
#B0122: Accelerator Sensor 1 (Low voltage) .......................... 15-28
#B0223: —............................................................................... 15-30
#B0222: —............................................................................... 15-32
#B1646: —............................................................................... 15-34
#B1647: —............................................................................... 15-36
#B0228: Accelerrator sensor 3 (Excessive sensor output)...... 15-38
#B0227: Accelerrator sensor 3 (Insufficient sensor output)..... 15-40
#B1227: —............................................................................... 15-42
#B1126: Accelerrator sensor 3 failure (Foot pedal in open position)
................................................................................................. 15-43
#B1125: Accelerrator sensor 3 failure (Foot pedal in closed position)
................................................................................................. 15-45
Intake throttle opening sensor ...................................................... 15-46
#B02E9: Intake Throttle Open Position Sens Error (High V) ... 15-46
#B02E8: Intake Throttle Open Position Sens Error (Low V).... 15-48
EGR low pressure side sensor..................................................... 15-50
#B0238: EGR Low Pressure Side Sensor Error (High Voltage) 15-50
#B0237: EGR Low Pressure Side Sensor Error (Low Voltage)15-52
#B0236: EGR Low Pres Side Sens Error (Abnorm Learn Value)
................................................................................................. 15-54

86E-7 – 98E-7 Series 15-1

FAILURE CODE (DTC) GENERAL DESCRIPTION

EGR high pressure side sensor ....................................................15-56

#B0473: EGR High Pressure Side Sensor Error (High Voltage) .. 15-56
#B0472: EGR High Pressure Side Sensor Error (Low Voltage) ...15-58
#B0471: EGR High Pres Side Sens Error (Abnorm Learn Value)
..................................................................................................15-60
Cooling water temperature sensor ................................................15-62
#B0118: Cooling Water Temperature Sens Error (High Volt)...15-62
#B0117: Cooling Water Temperature Sensor Error (Low Volt) .. 15-64
#B0217: —................................................................................15-66
New air temperature sensor..........................................................15-68
#B0113: New Air Temperature Sensor Error (High Voltage)....15-68
#B0112: New Air Temperature Sensor Error (Low Voltage) ....15-70
Fuel temperature sensor ...............................................................15-72
#B0183: Fuel Temperature Sensor Error (High Voltage) .........15-72
#B0182: Fuel Temperature Sensor Error (Low Voltage) ..........15-74
#B0168: Fuel Temperature Sensor Temperature Abnormal High
..................................................................................................15-76
Rail pressure sensor .....................................................................15-78
#B0193: Rail Pressure Sensor Error (High Voltage) ................15-78
#B0192: Rail Pressure Sensor Error (Low Voltage) .................15-80
KDPF differential pressure sensor ................................................15-82
#B2455: KDPF Differential Pressure Sens Error (High Volt)....15-82
#B2454: KDPF Differential Pressure Sens Error (Low Volt).....15-84
#B2452: KDPF Differential Pressure High Error.......................15-86
#B2453: KDPF Different Press Sens (Abnormal Learn Value) .. 15-88
KDPF high pressure side sensor ..................................................15-90
#B1455: KDPF High Pressure Side Sens Error (High Volt) .....15-90
#B1454: KDPF High Pressure Side Sensor Error (Low Voltage)
..................................................................................................15-92
KDPF inlet temperature sensor.....................................................15-94
#B1428: KDPF Inlet Temperature Sensor Error (High Voltage). 15-94
#B1427: KDPF Inlet Temperature Sensor Error (Low Voltage) . 15-96
#B1436: KDPF Inlet Temperature High Error...........................15-98
KDPF intermediate temperature sensor........................................15-99
#B1434: KDPF Intermediate Temperature Sens Error (HighVolt)
..................................................................................................15-99
#B1435: KDPF Intermediate Temperature Sens Error (LowVolt)
................................................................................................15-101
#B0420: KDPF Inter Temperature Low Error .........................15-103
#B1426: KDPF InterTemperature High Error (Post-injection) .. 15-104
Atmospheric pressure sensor .....................................................15-105
#B2229: Ambient Pressure Sensor Error (High Voltage) .......15-105
#B2228: Ambient Pressure Sensor Error (Low Voltage) ........15-106
#B1231: Ambient Pressure Sensor Characteristic Error ........15-107
EGR gas temperature sensor .....................................................15-109
#B041D: EGR Gas Temperature Sensor Error (High Voltage) 15-109
#B041C: EGR Gas Temperature Sensor Error (Low Voltage). 15-111
Intake manifold temperature sensor............................................15-113
#B040D: Intake Manifold Temperature Sens Error (High Volt)...15-113
#B040C: Intake Manifold Temperature Sens Error (Low Volt)....15-115
Exhaust manifold temperature sensor ........................................15-117
#B0546: Exhaust Manifold Temperature Sens Error (HighVolt) .15-117
#B0545: Exhaust Manifold Temperature Sens Error (Low Volt).15-119

15-2 86E-7 – 98E-7 Series

 FAILURE CODE (DTC) GENERAL DESCRIPTION

Contact output related ...................................................................... 15-121

Main relay................................................................................... 15-121
#B068B: Main Relay Contact Stuck....................................... 15-121
#B068A: Main Relay Early Opening ...................................... 15-123
Startup assist relay..................................................................... 15-125
#B0543: Startup Assist Relay Open Circuit ........................... 15-125
#B0541: Startup Assist Relay GND Short Circuit .................. 15-127
CRS (common rail system) related .................................................. 15-129
Injector 4..................................................................................... 15-129
#B0204 (4-cylinder engine): Injector of 4th Cylinder OpenC
(Inherent Location)
#B0203 (3-cylinder engine): — .............................................. 15-129
#B0271 (4-cylinder engine): Injector of 4th Cylinder Coil Short Circuit
#B0268 (3-cylinder engine): — .............................................. 15-131
#B1271 (4-cylinder engine): Injector of 4th Cylinder Short Circuit
#B1268 (3-cylinder engine): — .............................................. 15-133
Injector 2..................................................................................... 15-135
#B0202: Injector of 2nd Cylinder OpenC (Inherent Location) .. 15-135
#B0265: Injector of 2nd Cylinder Coil Short Circuit ............... 15-137
#B1265: Injector of 2nd Cylinder Short Circuit....................... 15-139
Injector 1..................................................................................... 15-141
#B0201: Injector of 1st Cylinder OpenC (Inherent Location).... 15-141
#B0262: Injector of 1st Cylinder Coil Short Circuit................. 15-143
#B1262: Injector of 1st Cylinder Short Circuit........................ 15-145
Injector 3..................................................................................... 15-147
#B0203 (4-cylinder engine): Injector of 3rd Cylinder OpenC
(Inherent Location) ..................................................................15-147
#B0268 (4-cylinder engine): Injector of 3rd Cylinder Coil Short Circuit
............................................................................................... 15-149
#B1268 (4-cylinder engine): Injector of 3rd Cylinder Short Circuit
............................................................................................... 15-151
Injector (common) ...................................................................... 15-153
#B0611: Injector Drive IC Error.............................................. 15-153
#B1146: Injector Drive Circuit (Bank1) Short Circuit.............. 15-154
#B1149: Injector Drive Circuit (Bank2) Short Circuit.............. 15-156
#B1648: Injector of 1st Cylinder Compensation Value Error.... 15-158
#B1649: Injector of 2nd Cylinder Compensation Value Error... 15-159
#B1650: Injector of 3rd Cylinder Compensation Value Error ... 15-160
#B1651: Injector of 4th Cylinder Compensation Value Error.... 15-161
SCV (MPROP) ........................................................................... 15-162
#B1641: SCV (MPROP) (Low Side VB Short)....................... 15-162
#B1643: SCV (MPROP) (Low Side GND Short).................... 15-163
#B0629: SCV (MPROP) (High Side VB Short) ...................... 15-165
#B1642: SCV (MPROP) (High Side GND Short)................... 15-167
#B0627: SCV (MPROP) (Open Circuit) ................................. 15-168
#B062A: SCV (MPROP) (Drive Current High Error).............. 15-169
#B1645: SCV (MPROP) (Pump Overload Error) ................... 15-171
Abnormal rail pressure ............................................................... 15-173
#B0088: Actual Rail Pressure Rise Error............................... 15-173
#B0094: Rail Press Deviation Error in Act Rail Press Drop... 15-175
#B0093: Rail Press Deviation Error in Act Rail Press Rise ... 15-177

86E-7 – 98E-7 Series 15-3

FAILURE CODE (DTC) GENERAL DESCRIPTION

PLV (Common rail pressure limit valve) ......................................15-179

#B000F: PLV Open Valve ......................................................15-179
#B1666: PLV (Number of times of PLV Valve Opening Error) . 15-181
#B1667: PLV (Time of PLV Valve Opening Error)..................15-183
#B1668: PLV (Non-Performance)...........................................15-185
#B1665: PLV (Malfunction).....................................................15-187
Rail pressure control ...................................................................15-189
#B1669: Rail Press Control (Fuel Temp High in PLV V Open) 15-189
#B1670: Rail Press Control (Pump or Fuel Temp Error) ........15-191
Actuator.............................................................................................15-192
Intake throttle drive circuit ...........................................................15-192
#B0660: No-load of Throttle Valve Drive H Bridge Circuit......15-192
#B1658: Power Short of Throttle Valve Drive H Bridge Out 1 .. 15-193
#B1659: GND Short of Throttle Valve Drive H Bridge Out 1 ..15-194
#B1660: O-load on the Drive H Bridge Cir of Throttle Valve ..15-195
#B1661: VB P Short of Throttle Valve Drive H Bridge Out 2 ..15-196
#B1662: GND Short of Throttle Valve Drive H Bridge Out 2 ..15-197
EGR ............................................................................................15-198
#B0404: EGR Voltage High Error...........................................15-198
#B1404: EGR Voltage Low Error............................................15-199
#B1409: EGR Feedback Error................................................15-200
#BG401: EGR ECM Data Error ..............................................15-201
#B0403: Open Circuit Between the EGR Motor Coils ............15-202
#B1405: Short Circuit Between the EGR Motor Coils ............15-203
#B0488: EGR Position Sensor Error ......................................15-204
#B148A: EGR Stuck Open Valve Error ..................................15-205
#B049D: EGR Initialization Error ............................................15-206
#BH401: EGR Target Value Out of Range.............................15-207
#B1410: EGR High Temperature Thermistor Error ................15-208
#B1411: EGR Low Temperature Thermistor Error .................15-209
Exhaust throttle ...........................................................................15-210
#B1438: Exhaust throttle (Voltage fault).................................15-210
#B1439: Exhaust throttle (Motor fault)....................................15-211
#B1440: Exhaust throttle (Sensor system fault) .....................15-212
#B1441: Exhaust throttle (MPU fault) .....................................15-213
#B1442: Exhaust throttle (PCB fault)......................................15-214
#B1443: Exhaust throttle (CAN fault) .....................................15-215
Communication related .....................................................................15-216
CAN1...........................................................................................15-216
#BG10B: CAN1 (for EGR): Reception Time Out ....................15-216
#BH107: Exhaust throttle
(CAN message from the exhaust throttle time out) ................15-217
CAN2...........................................................................................15-218
#BG292: TSC1 (CAN Message) Reception Time Out (SA1) .15-218
#BH301: TSC1 (CAN Message) Reception Time Out (SA2)..15-220
#BH292: Y_ECR1 (CAN Message) Reception Time Out .......15-222
#BH293: Y_EC (CAN Message) Reception Time Out............15-224
#BH294: — .............................................................................15-226
#BH296: — .............................................................................15-228
#BH298: — .............................................................................15-230

15-4 86E-7 – 98E-7 Series

 FAILURE CODE (DTC) GENERAL DESCRIPTION

#BG168: — ............................................................................ 15-232

#BK002: — ............................................................................ 15-234
#BH300: — ............................................................................ 15-236
#BH302: — ............................................................................ 15-238
#BH303: Y_DPFIF (CAN Message) Reception Time Out ..... 15-240
ECU related...................................................................................... 15-242
EEPROM.................................................................................... 15-242
#B0601: EEPROM Memory Deletion Error............................ 15-242
#B160E: EEPROM Memory Read Error................................ 15-243
#B160F: EEPROM Memory Writing Error ............................. 15-244
ECU internal fault ....................................................................... 15-245
#B1613: CY146 SPI Communication Error............................ 15-245
#B1608: Excessive Voltage of Supply 1 ................................ 15-246
#B1617: Insufficient Voltage of Supply 1 ............................... 15-247
#B1609: Sensor Supply Voltage Error 1................................ 15-248
#B1618: Sensor Supply Voltage Error 2................................ 15-249
#B1619: Sensor Supply Voltage Error 3................................ 15-250
#B1626: Actuator Drive Circuit 1 Short to Ground................. 15-251
#B1633: Actuator Drive Circuit 2 Short to Ground................. 15-252
#B1467: Actuator Drive Circuit 3 Short to Ground................. 15-253
#B1469: AD Converter Error 1............................................... 15-254
#B1470: AD Converter Error 2............................................... 15-255
#B1471: External Monitoring IC and CPU Error 1 ................. 15-256
#B1472: External Monitoring IC and CPU Error 2 ................. 15-257
#B1473: ROM Error ............................................................... 15-258
#B1474: Shutoff Path Error 1................................................. 15-259
#B1475: Shutoff Path Error 2................................................. 15-260
#B1476: Shutoff Path Error 3................................................. 15-261
#B1477: Shutoff Path Error 4................................................. 15-262
#B1478: Shutoff Path Error 5................................................. 15-263
#B1479: Shutoff Path Error 6................................................. 15-264
#B1480: Shutoff Path Error 7................................................. 15-265
#B1481: Shutoff Path Error 8................................................. 15-266
#B1482: Shutoff Path Error 9................................................. 15-267
#B1483: Shutoff Path Error 10............................................... 15-268
#B1484: Recognition Error of Engine Speed......................... 15-269
Contact input related ........................................................................ 15-270
Air cleaner switch ....................................................................... 15-270
#B1101: —............................................................................. 15-270
Oil/water separator switch .......................................................... 15-272
#B1151: —............................................................................. 15-272
Charge switch............................................................................. 15-274
#B1562: Charge Switch Open Circuit .................................... 15-274
#B1568: Charge Alarm .......................................................... 15-276
Oil pressure switch ..................................................................... 15-278
#B1192: Oil Pressure Switch Open Circuit ............................ 15-278
#B1198: Oil Pressure Low Error Alarm.................................. 15-280
Post treatment control ...................................................................... 15-282
KDPF.......................................................................................... 15-282
#B2463: Overaccumulation (Method C) ................................ 15-282
#B1463: Overaccumulation (Method P)................................. 15-283
#B2458: Defective Regeneration (StationaryRegene. Failure) ...15-284
#B2459: Defective Regeneration (StationaryR Not Performed)..15-285

86E-7 – 98E-7 Series 15-5

FAILURE CODE (DTC) GENERAL DESCRIPTION

KDPF OP interface......................................................................15-286
#B242F: Ash Cleaning Request 1 ..........................................15-286
#B1420: Ash Cleaning Request 2 ..........................................15-287
#B1421: Stationary Regeneration Standby ............................15-288
#B1424: Backup Mode ...........................................................15-289
#B1425: —..............................................................................15-290
#B1445: —..............................................................................15-291
#B1446: —..............................................................................15-292
Others ...............................................................................................15-293
Overspeed...................................................................................15-293
#B0219: Overspeed................................................................15-293
#BG167: Immobilizer CAN Communication Error ..................15-294
#BG426: Immobilizer System Error ........................................15-296

15-6 86E-7 – 98E-7 Series

Failure code (DTC) list FAILURE CODE (DTC) GENERAL DESCRIPTION

Failure code (DTC) list

Error item ECU Reference page
Failure
Failure phenomenon genera-
code Descrip- Failure
(Display of screen) Part State tion
(DTC) tion diagnosis
code
#B0336 Crank Signal Error Crank signal malfunction P0336 P15-15 P16-7
Crank speed sensor
#B0337 No Crank Signal No crank signal P0337 P15-17 P16-7
#B0341 Cam Signal Error Cam signal malfunction P0341 P15-19 P16-10
#B0342 No Cam Signal Cam speed sensor No cam signal P0342 P15-21 P16-10
#B1341 Cam Angle Offset Error Angle offset failure P1341 P15-23 –
No Signal on Both Crank and Cam Crank speed, Cam speed sen- P16-7,
#B0008 No signal on both crank and cam speed sensor P0008 P15-25
Speed Sensor sor P16-10
#B0123 Accelerator Sensor 1 (High voltage) Accelerator sensor 1 (Excessive sensor output) P0123 P15-26 P16-14
Accelerator sensor 1
#B0122 Accelerator Sensor 1 (Low voltage) Accelerator sensor 1 (Insufficient sensor output) P0122 P15-28 P16-14

#B0223 — Accelerator sensor 2 (Excessive sensor output) P0223 P15-30 P16-14

Accelerator sensor 2
#B0222 — Accelerator sensor 2 (Insufficient sensor output) P0222 P15-32 P16-14
#B1646 — Dual accelerator sensor (closed position) failure P1646 P15-34 –
Accelerator sensor 1 + 2
#B1647 — Dual accelerator sensor (open position) failure P1647 P15-36 –
Accelerrator sensor 3 (Excessive
#B0228 Accelerator sensor 3 (Excessive sensor output) P0228 P15-38 P16-14
sensor output)
Accelerator sensor 3
Accelerrator sensor 3 (Insufficient
#B0227 Accelerator sensor 3 (Insufficient sensor output) P0227 P15-40 P16-14
sensor output)
#B1227 — Pulse sensor Pulse sensor failure (Pulse communication) P1227 P15-42 –
Accelerrator sensor 3 failure (Foot
#B1126 Accelerator sensor 3 failure (Foot pedal in open position) P1126 P15-43 –
pedal in open position)
Accelerator sensor 3
Accelerrator sensor 3 failure
#B1125 Accelerator sensor 3 failure (Foot pedal in closed position) P1125 P15-45 –
(Foot pedal in closed position)
Intake Throttle Open Position Sens
#B02E9 Intake throttle opening sensor fault (High voltage) P02E9 P15-46 P16-18
Error (High V)
Intake throttle opening sensor
Intake Throttle Open Position Sens
#B02E8 Intake throttle opening sensor fault (Low voltage) P02E8 P15-48 P16-18
Error (Low V)
EGR Low Pressure Side Sensor
#B0238 EGR low pressure side sensor fault (High voltage) P0238 P15-50 P16-21
Error (High Voltage)
EGR Low Pressure Side Sensor
#B0237 EGR low pressure side sensor EGR low pressure side sensor fault (Low voltage) P0237 P15-52 P16-21
Error (Low Voltage)
EGR Low Pres Side Sens Error
#B0236 EGR low pressure side sensor (Abnormal learning value) P0236 P15-54 P16-21
(Abnorm Learn Value)
EGR High Pressure Side Sensor
#B0473 EGR high pressure side sensor fault (High voltage) P0473 P15-56 P16-24
Error (High Voltage)
EGR High Pressure Side Sensor
#B0472 EGR high pressure side sensor EGR high pressure side sensor fault (Low voltage) P0472 P15-58 P16-24
Error (Low Voltage)
EGR High Pres Side Sens Error
#B0471 EGR high pressure side sensor (Abnormal learning value) P0471 P15-60 P16-24
(Abnorm Learn Value)
Cooling Water Temperature Sens
#B0118 Cooling water temperature sensor fault (High voltage) P0118 P15-62 P16-27
Error (High Volt)
Cooling Water Temperature Sensor Cooling water temperature sen-
#B0117 Cooling water temperature sensor fault (Low voltage) P0117 P15-64 P16-27
Error (Low Volt) sor
Cooling water temperature sensor temperature abnormal
#B0217 — P0217 P15-66 P16-27
high (Overheat)
New Air Temperature Sensor Error
#B0113 New air temperature sensor fault (High voltage) P0113 P15-68 P16-31
(High Voltage)
New air temperature sensor
New Air Temperature Sensor Error
#B0112 New air temperature sensor fault (Low voltage) P0112 P15-70 P16-31
(Low Voltage)

86E-7 – 98E-7 Series 15-7

FAILURE CODE (DTC) GENERAL DESCRIPTION Failure code (DTC) list

Error item ECU Reference page

Failure
Failure phenomenon genera-
code Descrip- Failure
(Display of screen) Part State tion
(DTC) tion diagnosis
code
Fuel Temperature Sensor Error
#B0183 Fuel temperature sensor fault (High voltage) P0183 P15-72 P16-35
(High Voltage)
Fuel Temperature Sensor Error
#B0182 Fuel temperature sensor Fuel temperature sensor fault (Low voltage) P0182 P15-74 P16-35
(Low Voltage)
Fuel Temperature Sensor Tempera-
#B0168 Fuel temperature sensor temperature abnormal high P0168 P15-76 P16-35
ture Abnormal High
Rail Pressure Sensor Error
#B0193 Rail pressure sensor fault (High voltage) P0193 P15-78 P16-39
(High Voltage)
Rail pressure sensor
Rail Pressure Sensor Error
#B0192 Rail pressure sensor fault (Low voltage) P0192 P15-80 P16-39
(Low Voltage)
KDPF Differential Pressure Sens
#B2455 KDPF differential pressure sensor fault (High voltage) P2455 P15-82 P16-42
Error (High Volt)
KDPF Differential Pressure Sens
#B2454 KDPF differential pressure sensor fault (Low voltage) P2454 P15-84 P16-42
Error (Low Volt) KDPF differential pressure sen-
KDPF Differential Pressure High sor KDPF differential pressure sensor differential pressure
#B2452 P2452 P15-86 P16-42
Error abnormal high
KDPF Different Press Sens KDPF differential pressure sensor (Abnormal learning
#B2453 P2453 P15-88 P16-42
(Abnormal Learn Value) value)
KDPF High Pressure Side Sens Error
#B1455 KDPF high pressure side sensor fault (High voltage) P1455 P15-90 P16-42
(High Volt) KDPF high pressure side sen-
KDPF High Pressure Side Sensor sor
#B1454 KDPF high pressure side sensor fault (Low voltage) P1454 P15-92 P16-42
Error (Low Voltage)
KDPF Inlet Temperature Sensor Error
#B1428 KDPF inlet temperature sensor fault (High voltage) P1428 P15-94 P16-46
(High Voltage)
KDPF Inlet Temperature Sensor Error KDPF inlet temperature sensor
#B1427 KDPF inlet temperature sensor fault (Low voltage) P1427 P15-96 P16-46
(Low Voltage)
#B1436 KDPF Inlet Temperature High Error KDPF inlet temperature sensor temperature abnormal high P1436 P15-98 P16-46
KDPF Intermediate Temperature KDPF intermediate temperature sensor fault (High volt-
#B1434 P1434 P15-99 P16-50
Sens Error (HighVolt) age)
KDPF Intermediate Temperature
#B1435 KDPF intermediate temperature sensor fault (Low voltage) P1435 P15-101 P16-50
Sens Error (LowVolt) KDPF intermediate temperature
sensor KDPF intermediate temperature sensor temperature
#B0420 KDPF Inter Temperature Low Error P0420 P15-103 P16-50
abnormal low temperature
KDPF InterTemperature High Error KDPF intermediate temperature sensor temperature
#B1426 P1426 P15-104 P16-50
(Post-injection) abnormal high (Post-injection failure)
Ambient Pressure Sensor Error
#B2229 Atmospheric pressure sensor fault (High voltage) P2229 P15-105 P16-107
(High Voltage)
Ambient Pressure Sensor Error
#B2228 Atmospheric pressure sensor Atmospheric pressure sensor fault (Low voltage) P2228 P15-106 P16-107
(Low Voltage)
Ambient Pressure Sensor Character-
#B1231 Atmospheric pressure sensor characteristic fault P1231 P15-107 P16-107
istic Error
EGR Gas Temperature Sensor Error
#B041D EGR gas temperature sensor fault (High voltage) P041D P15-109 P16-54
(High Voltage)
EGR gas temperature sensor
EGR Gas Temperature Sensor Error
#B041C EGR gas temperature sensor fault (Low voltage) P041C P15-111 P16-54
(Low Voltage)
Intake Manifold Temperature Sens
#B040D Intake manifold temperature sensor fault (High voltage) P040D P15-113 P16-58
Error (High Volt) Intake manifold temperature
Intake Manifold Temperature Sens sensor
#B040C Intake manifold temperature sensor fault (Low voltage) P040C P15-115 P16-58
Error (Low Volt)
Exhaust Manifold Temperature Sens
#B0546 Exhaust manifold temperature sensor fault (High voltage) P0546 P15-117 P16-62
Error (HighVolt) Exhaust manifold temperature
Exhaust Manifold Temperature Sens sensor
#B0545 Exhaust manifold temperature sensor fault (Low voltage) P0545 P15-119 P16-62
Error (Low Volt)
#B068B Main Relay Contact Stuck Main relay contact stuck P068B P15-121 P16-66
Main relay
#B068A Main Relay Early Opening Main relay early opening P068A P15-123 P16-66

15-8 86E-7 – 98E-7 Series

Failure code (DTC) list FAILURE CODE (DTC) GENERAL DESCRIPTION

Error item ECU Reference page

Failure
Failure phenomenon genera-
code Descrip- Failure
(Display of screen) Part State tion
(DTC) tion diagnosis
code
#B0543 Startup Assist Relay Open Circuit Startup assist relay interrupted P0543 P15-125 P16-70
Startup Assist Relay GND Short Cir- Startup assist relay
#B0541 Startup assist relay GND interrupted P0541 P15-127 P16-70
cuit
Injector of 4th Cylinder OpenC (Inher-
#B0204 Injector 4 open circuit (Inherent location of the injector) P0204 P15-129 P16-81
ent Location)
Injector of 4th Cylinder Coil Short Cir- Injector 4 (4-cylinder engine)
#B0271 Injector 4 coil short circuit P0271 P15-131 P16-81
cuit
#B1271 Injector of 4th Cylinder Short Circuit Injector 4 short circuit P1271 P15-133 P16-85

#B0203 — Injector 3 open circuit (Inherent location of the injector) P0203 P15-129 P16-81

#B0268 — Injector 3 (3-cylinder engine) Injector 3 coil short circuit P0268 P15-131 P16-81

#B1268 — Injector 3 short circuit P1262 P15-133 P16-85

Injector of 2nd Cylinder OpenC

#B0202 Injector 2 open circuit (Inherent location of the injector) P0202 P15-135 P16-81
(Inherent Location)
Injector of 2nd Cylinder Coil Short Injector 2
#B0265 Injector 2 coil short circuit P0265 P15-137 P16-81
Circuit
#B1265 Injector of 2nd Cylinder Short Circuit Injector 2 short circuit P1265 P15-139 P16-85
Injector of 1st Cylinder OpenC
#B0201 Injector 1 open circuit (Inherent location of the injector) P0201 P15-141 P16-81
(Inherent Location)
Injector of 1st Cylinder Coil Short Cir- Injector 1
#B0262 Injector 1 coil short circuit P0262 P15-143 P16-81
cuit
#B1262 Injector of 1st Cylinder Short Circuit Injector 1 short circuit P1262 P15-145 P16-85
Injector of 3rd Cylinder OpenC
#B0203 Injector 3 open circuit (Inherent location of the injector) P0203 P15-147 P16-81
(Inherent Location)
Injector of 3rd Cylinder Coil Short Cir- Injector 3 (4-cylinder engine)
#B0268 Injector 3 coil short circuit P0268 P15-149 P16-81
cuit
#B1268 Injector of 3rd Cylinder Short Circuit Injector 3 short circuit P1268 P15-151 P16-85
#B0611 Injector Drive IC Error Injector drive IC error P0611 P15-153 –
Injector drive circuit (Bank1) short circuit
Injector Drive Circuit (Bank1) Short
#B1146 (4-cylinder engine: Common circuit for No. 1, No. 4 and all P1146 P15-154 P16-85
Circuit Injector (common)
3-cylinder engine cylinders)
Injector Drive Circuit (Bank2) Short Injector drive circuit (Bank 2) short circuit
#B1149 P1149 P15-156 P16-85
Circuit (4-cylinder engine: Circuit for No. 2 and No. 3 cylinders)
Injector of 1st Cylinder Compensation
#B1648 IQA corrected injection amount for injector 1 error P1648 P15-158 –
Value Error
Injector of 2nd Cylinder Compensa-
#B1649 IQA corrected injection amount for injector 2 error P1649 P15-159 –
tion Value Error
Injector (correction value)
Injector of 3rd Cylinder Compensa-
#B1650 IQA corrected injection amount for injector 3 error P1650 P15-160 –
tion Value Error
Injector of 4th Cylinder Compensation
#B1651 IQA corrected injection amount for injector 4 error P1651 P15-161 –
Value Error
#B1641 SCV(MPROP) (Low Side VB Short) High-pressure pump drive circuit (Low side VB short-circuit) P1641 P15-162 P16-87
#B1643 SCV(MPROP) (Low Side GND Short) High-pressure pump drive circuit (Low side GND short-circuit) P1643 P15-163 P16-87
#B0629 SCV(MPROP) (High Side VB Short) High-pressure pump drive circuit (High side VB short-circuit) P0629 P15-165 P16-87
SCV(MPROP) (High Side GND
#B1642 High-pressure pump drive circuit (High side GND short-circuit) P1642 P15-167 P16-87
Short)
SCV (MPROP)
#B0627 SCV(MPROP) (Open Circuit) High-pressure pump drive circuit (Open circuit) P0627 P15-168 P16-87
SCV(MPROP) (Drive Current High
#B062A High-pressure pump drive circuit (Drive current (high level)) P062A P15-169 P16-87
Error)
SCV(MPROP) (Pump Overload
#B1645 High-pressure pump drive circuit (Pump overload error) P1645 P15-171 P16-87
Error)

86E-7 – 98E-7 Series 15-9

FAILURE CODE (DTC) GENERAL DESCRIPTION Failure code (DTC) list

Error item ECU Reference page

Failure
Failure phenomenon genera-
code Descrip- Failure
(Display of screen) Part State tion
(DTC) tion diagnosis
code
#B0088 Actual Rail Pressure Rise Error Actual rail pressure rise error P0088 P15-173 –
Rail Press Deviation Error in Act Rail Rail pressure deviation error during the actual rail pressure
#B0094 P0094 P15-175 –
Press Drop Abnormal rail pressure drop
Rail Press Deviation Error in Act Rail Rail pressure deviation error during the actual rail pressure
#B0093 P0093 P15-177 –
Press Rise rise
#B000F PLV Open Valve PLV open valve P000F P15-179 –
PLV (Number of times of PLV Valve
#B1666 Rail pressure fault (The times of PLV valve opening error) P1666 P15-181 –
Opening Error)
#B1667 PLV (Time of PLV Valve Opening Error) PLV (Common rail pressure Rail pressure fault (The time of PLV valve opening error) P1667 P15-183 –
limit valve)
Rail pressure fault (The actual rail pressure is too high
#B1668 PLV (Non-Performance) P1668 P15-185 –
during PRV limp home)
Rail pressure fault (Controlled rail pressure error after PLV
#B1665 PLV (Malfunction) P1665 P15-187 –
valve opening)
Rail Press Control Rail pressure fault (Injector B/F temperature error during
#B1669 P1669 P15-189 –
(Fuel Temp High in PLV V Open) PLV4 limp home)
Rail pressure control
Rail Press Control Rail pressure fault (Operation time error during RPS limp
#B1670 P1670 P15-191 –
(Pump or Fuel Temp Error) home)
#B0219 Overspeed Overspeed Overspeed P0219 P15-293 P16-110
No-load of Throttle Valve Drive H
#B0660 No-load of throttle valve drive H bridge circuit P0660 P15-192 P16-90
Bridge Circuit
Power Short of Throttle Valve Drive H
#B1658 Power short circuit of throttle valve drive H bridge output 1 P1658 P15-193 P16-90
Bridge Out 1
GND Short of Throttle Valve Drive H
#B1659 GND short circuit of throttle valve drive H bridge output 1 P1659 P15-194 P16-90
Bridge Out 1
Intake throttle drive circuit
O-load on the Drive H Bridge Cir of
#B1660 Overload on the drive H bridge circuit of throttle valve P1660 P15-195 P16-90
Throttle Valve
VB P Short of Throttle Valve Drive H VB Power short circuit of throttle valve drive H bridge out-
#B1661 P1661 P15-196 P16-90
Bridge Out 2 put 2
GND Short of Throttle Valve Drive H
#B1662 GND short circuit of throttle valve drive H bridge output 2 P1662 P15-197 P16-90
Bridge Out 2
TSC1 (CAN Message) Reception
#BG292 TSC1 (CAN message) reception time out (SA1) U0292 P15-218 P16-104
Time Out (SA1)
TSC1 (CAN Message) Reception
#BH301 TSC1 (CAN message) reception time out (SA2) U1301 P15-220 P16-104
Time Out (SA2)
Y_ECR1 (CAN Message) Reception
#BH292 Y_ECR1 (CAN message) reception time out U1292 P15-222 P16-104
Time Out
Y_EC (CAN Message) Reception
#BH293 Y_EC (CAN message) reception time out U1293 P15-224 P16-104
Time Out

#BH294 — Y_RSS (CAN message) reception time out U1294 P15-226 P16-104

#BH296 — CAN2 VH (CAN message) reception time out U1296 P15-228 P16-104

#BH298 — Y_ECM3 (CAN message) reception time out U1298 P15-230 P16-104

#BG168 — VI (CAN message) reception time out U0168 P15-232 P16-104

#BK002 — VI (CAN message) reception data fault U3002 P15-234 P16-104

#BH300 — Y_ETCP1 (CAN message) reception time out U1300 P15-236 P16-104

#BH302 — EBC1 (CAN message) reception time out U1302 P15-238 P16-104

Y_DPFIF (CAN Message) Reception

#BH303 Y_DPFIF (CAN message) reception time out U1303 P15-240 P16-104
Time Out
#BG10B CAN1 (for EGR): Reception Time Out CAN1 (for EGR): Reception time out U010B P15-216 P16-101
Exhaust throttle (CAN message from CAN1 Exhaust throttle (CAN message from the exhaust throttle
#BH107 U1107 P15-217 P16-101
the exhaust throttle time out) time out)
Immobilizer CAN Communication
#BG167 Immobilizer CAN Communication Error U0167 P15-294 P16-112
Error Immobilizer
#BG426 Immobilizer System Error Immobilizer System Error U0426 P15-296 P16-112

15-10 86E-7 – 98E-7 Series

Failure code (DTC) list FAILURE CODE (DTC) GENERAL DESCRIPTION

Error item ECU Reference page

Failure
Failure phenomenon genera-
code Descrip- Failure
(Display of screen) Part State tion
(DTC) tion diagnosis
code
#B0404 EGR Voltage High Error EGR over-voltage fault P0404 P15-198 P16-95
#B1404 EGR Voltage Low Error EGR under-voltage fault P1404 P15-199 P16-95
#B1409 EGR Feedback Error EGR feedback malfunction P1409 P15-200 P16-99
#BG401 EGR ECM Data Error EGR ECM data fault U0401 P15-201 P16-99
Open Circuit Between the EGR Motor
#B0403 Open circuit between the EGR motor coils P0403 P15-202 P16-99
Coils
Short Circuit Between the EGR Motor
#B1405 Short circuit between the EGR motor coils P1405 P15-203 P16-99
Coils
EGR valve
#B0488 EGR Position Sensor Error EGR position sensor malfunction P0488 P15-204 P16-99
#B148A EGR Stuck Open Valve Error EGR stuck open valve malfunction P148A P15-205 P16-99
#B049D EGR Initialization Error EGR initialization malfunction P049D P15-206 P16-99
EGR High Temperature Thermistor
#B1410 EGR high temperature thermistor malfunction P1410 P15-208 P16-99
Error
EGR Low Temperature Thermistor
#B1411 EGR low temperature thermistor malfunction P1411 P15-209 P16-99
Error
#BH401 EGR Target Value Out of Range EGR target value out of range U1401 P15-207 P16-99
#B1438 Exhaust throttle (Voltage fault) Exhaust throttle (Voltage fault) P1438 P15-210 –
#B1439 Exhaust throttle (Motor fault) Exhaust throttle (Motor fault) P1439 P15-211 –
#B1440 Exhaust throttle (Sensor system fault) Exhaust throttle (Sensor system fault) P1440 P15-212 –
Exhaust throttle
#B1441 Exhaust throttle (MPU fault) Exhaust throttle (MPU fault) P1441 P15-213 –
#B1442 Exhaust throttle (PCB fault) Exhaust throttle (PCB fault) P1442 P15-214 –
#B1443 Exhaust throttle (CAN fault) Exhaust throttle (CAN fault) P1443 P15-215 –
#B0601 EEPROM Memory Deletion Error EEPROM memory deletion error P0601 P15-242 P16-107
#B160E EEPROM Memory Read Error EEPROM EEPROM memory read error P160E P15-243 P16-107
#B160F EEPROM Memory Writing Error EEPROM memory writing error P160F P15-244 P16-107
#B1613 CY146 SPI Communication Error CY146 SPI communication fault P1613 P15-245 P16-107
#B1608 Excessive Voltage of Supply 1 Excessive voltage of supply 1 P1608 P15-246 P16-107
#B1617 Insufficient Voltage of Supply 1 Insufficient voltage of supply 1 P1617 P15-247 P16-107
#B1609 Sensor Supply Voltage Error 1 Sensor supply voltage error 1 P1609 P15-248 –
#B1618 Sensor Supply Voltage Error 2 Sensor supply voltage error 2 P1618 P15-249 –
#B1619 Sensor Supply Voltage Error 3 Sensor supply voltage error 3 P1619 P15-250 –
Actuator Drive Circuit 1 Short to
#B1626 Actuator drive circuit 1 short to ground P1626 P15-251 –
Ground
Actuator Drive Circuit 2 Short to
#B1633 Actuator drive circuit 2 short to ground P1633 P15-252 –
Ground
Actuator Drive Circuit 3 Short to
#B1467 Actuator drive circuit 3 short to ground P1467 P15-253 –
Ground
#B1469 AD Converter Error 1 ECU internal fault AD converter fault 1 P1469 P15-254 P16-107
#B1470 AD Converter Error 2 AD converter fault 2 P1470 P15-255 P16-107
External Monitoring IC and CPU Error
#B1471 External monitoring IC and CPU fault 1 P1471 P15-256 P16-107
1
External Monitoring IC and CPU Error
#B1472 External monitoring IC and CPU fault 2 P1472 P15-257 P16-107
2
#B1473 ROM Error ROM fault P1473 P15-258 P16-107
#B1474 Shutoff Path Error 1 Shutoff path fault 1 P1474 P15-259 P16-107
#B1475 Shutoff Path Error 2 Shutoff path fault 2 P1475 P15-260 P16-107
#B1476 Shutoff Path Error 3 Shutoff path fault 3 P1476 P15-261 P16-108
#B1477 Shutoff Path Error 4 Shutoff path fault 4 P1477 P15-262 P16-108
#B1478 Shutoff Path Error 5 Shutoff path fault 5 P1478 P15-263 P16-108
#B1479 Shutoff Path Error 6 Shutoff path fault 6 P1479 P15-264 P16-108

86E-7 – 98E-7 Series 15-11

FAILURE CODE (DTC) GENERAL DESCRIPTION Failure code (DTC) list

Error item ECU Reference page

Failure
Failure phenomenon genera-
code Descrip- Failure
(Display of screen) Part State tion
(DTC) tion diagnosis
code
#B1480 Shutoff Path Error 7 Shutoff path fault 7 P1480 P15-265 P16-108
#B1481 Shutoff Path Error 8 Shutoff path fault 8 P1481 P15-266 P16-108
#B1482 Shutoff Path Error 9 ECU internal fault Shutoff path fault 9 P1482 P15-267 P16-108
#B1483 Shutoff Path Error 10 Shutoff path fault 10 P1483 P15-268 P16-108
#B1484 Recognition Error of Engine Speed Recognition error of engine speed P1484 P15-269 –
#B1101 — Air cleaner switch Air cleaner clogged alarm P1101 P15-270 P16-78
#B1151 — Oil/water separator switch Oil/water separator alarm P1151 P15-272 P16-78
#B1562 Charge Switch Open Circuit Charge switch open circuit P1562 P15-274 P16-74
Charge switch
#B1568 Charge Alarm Charge alarm P1568 P15-276 P16-74
#B1192 Oil Pressure Switch Open Circuit Oil pressure switch open circuit P1192 P15-278 P16-74
Oil pressure switch
#B1198 Oil Pressure Low Error Alarm Low oil pressure fault alarm P1198 P15-280 P16-74
#B2463 Overaccumulation (Method C) Overaccumulation (Method C) P2463 P15-282 –
#B1463 Overaccumulation (Method P) Overaccumulation (Method P) P1463 P15-283 –
Defective Regeneration (Station- KDPF
#B2458 Regeneration defect (Stationary regeneration failure) P2458 P15-284 –
aryRegene. Failure)
Defective Regeneration (StationaryR Regeneration defect (Stationary regeneration not per-
#B2459 P2459 P15-285 –
Not Performed) formed)
#B242F Ash Cleaning Request 1 Ash cleaning request 1 P242F P15-286 –
#B1420 Ash Cleaning Request 2 Ash cleaning request 2 P1420 P15-287 –
#B1421 Stationary Regeneration Standby Stationary regeneration standby P1421 P15-288 –
#B1424 Backup Mode KDPF OP interface Backup mode P1424 P15-289 –
#B1425 — Reset regeneration prohibited P1425 P15-290 –
#B1445 — Recovery regeneration failure P1445 P15-291 –
#B1446 — Recovery regeneration prohibition P1446 P15-292 –

15-12 86E-7 – 98E-7 Series

Failure code (DTC) list FAILURE CODE (DTC) GENERAL DESCRIPTION

Indication of Diagnostic Trouble Code (DTC)

The failure code displayed on the machine monitor is different from DTC (Diagnostic Trouble Code) given by engine
controller (ECU).
You can check DTC of engine controller by using SMARTASSIST-DIRECT, and also you can translate it into the fail-
ure code displayed on the machine monitor by using the following relationship.
1. When a digit is in the 3rd place of the failure code displayed on the machine monitor

Failure code display on the machine monitor (6-digit) Failure code display on the SMARTASSIST-DIRECT (5-digit)
Digit 㻝 㻞 㻟 㻠 㻡 㻢 Digit 㻝 㻞 㻟 㻠 㻡
㻏 㻮 㻜 䐠 䐡 䐢 㻼 㻜 䐠 䐡 䐢
㻏 㻮 㻝 䐠 䐡 䐢 㻼 㻝 䐠 䐡 䐢
Character Character
㻏 㻮 㻞 䐠 䐡 䐢 㻼 㻞 䐠 䐡 䐢
㻏 㻮 㻟 䐠 䐡 䐢 㻼 㻟 䐠 䐡 䐢

㻏㻮㻌㻌㻌㻌㻼

Read the lower 4 digits as they are.

2. When an alphabet letter is in the 3rd place of the failure code displayed on the machine monitor

Failure code display on the machine monitor (6-digit) Failure code display on the SMARTASSIST-DIRECT (5-digit)
Digit 㻝 㻞 㻟 㻠 㻡 㻢 Digit 㻝 㻞 㻟 㻠 㻡
㻏 㻮 㻳 䐠 䐡 䐢 㼁 㻜 䐠 䐡 䐢
㻏 㻮 㻴 䐠 䐡 䐢 㼁 㻝 䐠 䐡 䐢
Character Character
㻏 㻮 㻶 䐠 䐡 䐢 㼁 㻞 䐠 䐡 䐢
㻏 㻮 㻷 䐠 䐡 䐢 㼁 㻟 䐠 䐡 䐢

㻏㻮㻌㻌㻌㻌㼁

㻾㼑㼜㼘㼍㼏㼑㻌㼠㼔㼑㻌㼘㼑㼠㼠㼑㼞㼟㻌㼍㼟㻌㼒㼛㼘㼘㼛㼣㼟㻧
㻌㻳㻌㻌㻌㻌㻜
㻌㻴㻌㻌㻌㻌㻝
㻌㻶㻌㻌㻌㻌㻌㻞
㻌㻷㻌㻌㻌㻌㻟

Read the lower 3 digits as they are.

Reference: DTC is a code defined by SAE J2012/ISO15031-1.

In the 1st place, B, C, P, or U is used.
In the 2nd place, 0, 1, 2, or 3 is used.
In the 3rd, 4th, and 5th places, hexadecimal numbers (0 to F) are used.

86E-7 – 98E-7 Series 15-13

FAILURE CODE (DTC) GENERAL DESCRIPTION Description

Description
6-digit alphanumeric character (DTC) : Display of failure name

Failure Failure phenomenon

6-digit alphanumeric character Error name
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Prerequisite for detecting the malfunction. Check points to specify the cause of the
2. Condition for detecting the malfunction. malfunction.
For details, refer to “Diagnosis Content”.

 Actions when a malfunction occurs

Fault mode [Continuous operation] / [Limited operation] / [Engine stop]:
Describes the engine operation when a malfunction is detected.


[Continuous operation]: The engine continues to operate without limitations after the malfunction is
detected.
Engine control is not obstructed.
[Limited operation]: The engine operation continues, but the high idle speed and engine power are
limited.
The engine output is limited.
[Engine stop]: The engine stops immediately when the malfunction is detected.
If the malfunction is detected prior to starting the engine, the starter does not turn.
Limited operation Yes/No: The details of limited operation at the time of the malfunction are listed.
Reset criteria Yes/No: The condition to release the fault mode is listed.
Remarks Safety precautions are listed.

 Presumed cause of the malfunction or the abnormal condition

Judging from the detected DTC, the presumed location and cause of the error (e.g. open circuit of sensor wiring) or
the abnormal condition of the system (e.g. abnormal increase of coolant temperature) are listed.
 Malfunctions related to the detected DTC are listed.

 Diagnosis
The method and procedure of the failure diagnosis are listed.

Note: If replacing the ECU, sensor or actuator fixes the malfunction, re-install the presumably broken parts and con-
firm that the malfunction re-occurs.

15-14 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

Sensor related

■ Crank speed sensor

#B0336: Crank Signal Error

Failure Failure phenomenon
#B0336 Crank Signal Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. Abnormal pulse detected for a constant number of times (15 times). Wire harness
Crank speed sensor
E-ECU
Pulser

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited. (The operation continues with only the cam.)
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Crank speed sensor failure
4. E-ECU internal circuit fault
5. Pulser fault and sensor installation condition fault

86E-7 – 98E-7 Series 15-15

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-7.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the crank speed sensor for deformation and cracks, the condition of the con-
nection, and whether the retainer is loose or removed.
• Check whether the crank speed sensor wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the crank speed sensor resistance value.

• Check the conduction of the wire harness.
• Check the crank speed sensor installation condition and the pulse.

 For details on the diagnosis method and procedure, see Chapter 16 P16-7.

15-16 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0337: No Crank Signal

Failure Failure phenomenon
#B0337 No Crank Signal
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. No crank pulser input while the cam is rotating for a certain number of rotations Wire harness
(2 rotations). Crank speed sensor
E-ECU
Pulser

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited. (The operation continues with only the cam.)
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Crank speed sensor failure
4. E-ECU internal circuit fault
5. Pulser fault and sensor installation condition fault

86E-7 – 98E-7 Series 15-17

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-7.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the crank speed sensor for deformation and cracks, the condition of the con-
nection, and whether the retainer is loose or removed.
• Check whether the crank speed sensor wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the crank speed sensor resistance value.

• Check the conduction of the wire harness.
• Check the crank speed sensor installation condition and the pulse.

 For details on the diagnosis method and procedure, see Chapter 16 P16-7.

15-18 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ Cam speed sensor

#B0341: Cam Signal Error

Failure Failure phenomenon
#B0341 Cam Signal Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. Incorrect cam pulser rotation or position detected while the crank is rotating for Wire harness
a certain number of rotations (2 rotations). Cam speed sensor
E-ECU
Pulser

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
(The operation continues with only the crank.)
Limited operation No
Reset criteria Yes:The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Cam speed sensor fault
4. E-ECU internal circuit fault
5. Pulser fault and sensor installation condition fault

86E-7 – 98E-7 Series 15-19

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-10.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the cam speed sensor for deformation and cracks, the condition of the con-
nection, and whether the retainer is loose or removed.
• Check whether the cam speed sensor wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the E-ECU output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-10.

15-20 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0342: No Cam Signal

Failure Failure phenomenon
#B0342 No Cam Signal
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. No cam pulser input while the crank is rotating for a certain number of rotations Wire harness
(2.2 rotations). Cam speed sensor
E-ECU
Pulser

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
(The operation continues with only the crank.)
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Cam speed sensor fault
4. E-ECU internal circuit fault
5. Pulser fault and sensor installation condition fault

86E-7 – 98E-7 Series 15-21

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-10.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the cam speed sensor for deformation and cracks, the condition of the con-
nection, and whether the retainer is loose or removed.
• Check whether the cam speed sensor wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the E-ECU output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-10.

15-22 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1341: Cam Angle Offset Error

Failure Failure phenomenon
#B1341 Cam Angle Offset Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The condition with the phase difference of 30 degrees or larger, or -20 degrees Wire harness
or smaller between the cam and the crank is detected for 2 times. Cam speed sensor
E-ECU
Pulser

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Cam speed sensor fault
4. E-ECU internal circuit fault
5. Pulser fault and sensor installation condition fault

86E-7 – 98E-7 Series 15-23

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the crank speed sensor, cam speed sensor for deformation and cracks, the
condition of the connection, and whether the retainer is loose or removed.
• Check whether the cam speed sensor wiring is disconnected or the wiring coating is peeled.

3. Pulser check • Before beginning your work, be sure to turn off the ECU power.
• Check that there is no abnormality in distance and displacement of the pulser and the sensor.

4. Failure diagnosis • Check the conduction of the wire harness.

• Check the E-ECU output voltage.

15-24 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0008: No Signal on Both Crank and Cam Speed Sensor

Failure Failure phenomenon
#B0008 No Signal on Both Crank and Cam Speed Sensor
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. No. Wire harness
Crank speed, Cam speed sensor
E-ECU
Pulser

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Crank speed sensor fault and cam speed sensor fault occur at the same time
2. Starter system fault

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-7, P16-10.

2. Connector/wiring check • Before beginning your work, be sure to turn off the power switch.
• Check the pin of the crank speed sensor, cam speed sensor for deformation and cracks, the
condition of the connection, and whether the retainer is loose or removed.
• Check whether the crank speed sensor, cam speed sensor wiring is disconnected or the wiring
coating is peeled.
• If the starter is turned on but the engine does not turn, check the starter system.

3. Failure diagnosis • Perform the failure diagnosis on the crank speed sensor and cam speed sensor.

86E-7 – 98E-7 Series 15-25

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

■ Accelerator sensor

#B0123: Accelerator Sensor 1 (High voltage)

Failure Failure phenomenon
#B0123 Accelerator Sensor 1 (High voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The sensor voltage is 4.6 V or higher. Wire harness
Accelerator sensor
E-ECU

 Actions when a malfunction occurs

Backup accelerator sensor function
No Yes
Fault mode [Limited operation]: [Continuous operation]:
The engine is operated at the constant rotation Switched to the engine operation by the spare
speed. accelerator sensor.
Limited operation Yes: The target rotation speed is set to “target rota- No
tion speed when a malfunction occurs (by map
setting)” or “target rotation speed prior to
detecting a malfunction”.
Reset criteria Yes: The fault mode is released when the ECU Yes: The fault mode is released when the ECU
power is turned off while the normal voltage power off is detected.
value (0.2 V to 4.6 V) is supplied.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Accelerator sensor failure
4. E-ECU internal circuit fault

15-26 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-14.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the connector pin of the accelerator sensor for deformation and cracks, the condition of
the connection, and whether the retainer is loose or removed.
• Check whether the accelerator sensor wiring is cut or the wiring coating is peeled.

3. Failure diagnosis • Check the accelerator sensor resistance value.

• Check the conduction of the wire harness.
• Check the accelerator sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-14.

86E-7 – 98E-7 Series 15-27

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0122: Accelerator Sensor 1 (Low voltage)

Failure Failure phenomenon
#B0122 Accelerator Sensor 1 (Low voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The sensor voltage is 0.2 V or lower. Wire harness
Accelerator sensor
E-ECU

 Actions when a malfunction occurs

Backup accelerator sensor function
No Yes
Fault mode [Limited operation]: [Continuous operation]:
The engine is operated at the constant rotation Switched to the engine operation by the spare
speed. accelerator sensor.
Limited operation Yes: The target rotation speed is set to “target rota- No
tion speed when a malfunction occurs (by map
setting)” or “target rotation speed prior to
detecting a malfunction”.
Reset criteria Yes: The fault mode is released when the ECU Yes: The fault mode is released when the ECU
power is turned off while the normal voltage power off is detected.
value (0.2 V to 4.6 V) is supplied.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit or GND short circuit of sensor 5 V
3. Accelerator sensor failure
4. E-ECU internal circuit fault

15-28 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-14.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the connector pin of the accelerator sensor for deformation and cracks, the condition of
the connection, and whether the retainer is loose or removed.
• Check whether the accelerator sensor wiring is cut or the wiring coating is peeled.

3. Failure diagnosis • Check the accelerator sensor resistance value.

• Check the conduction of the wire harness.
• Check the accelerator sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-14.

86E-7 – 98E-7 Series 15-29

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0223: —
Failure Failure phenomenon
#B0223 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. Voltage of sensor signal is greater than the threshold value of 4.6 V. Wire harness
Accelerator sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit or GND short circuit of sensor 5 V
3. Accelerator sensor failure
4. E-ECU internal circuit fault

15-30 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-14.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the connector pin of the accelerator sensor for deformation and cracks, the condition of
the connection, and whether the retainer is loose or removed.
• Check whether the accelerator sensor wiring is cut or the wiring coating is peeled.

3. Failure diagnosis • Check the accelerator sensor resistance value.

• Check the conduction of the wire harness.
• Check the accelerator sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-14.

86E-7 – 98E-7 Series 15-31

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0222: —
Failure Failure phenomenon
#B0222 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. Voltage of sensor signal is less than the threshold value of 0.2 V. Wire harness
Accelerator sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit or GND short circuit of sensor 5 V
3. Accelerator sensor failure
4. E-ECU internal circuit fault

15-32 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-14.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the connector pin of the accelerator sensor for deformation and cracks, the condition of
the connection, and whether the retainer is loose or removed.
• Check whether the accelerator sensor wiring is cut or the wiring coating is peeled.

3. Failure diagnosis • Check the accelerator sensor resistance value.

• Check the conduction of the wire harness.
• Check the accelerator sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-14.

86E-7 – 98E-7 Series 15-33

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B1646: —
Failure Failure phenomenon
#B1646 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. (APS2 terminal voltage - Estimated APS2 terminal voltage) is greater than the Wire harness
[Detected value of the dual accelerator sensor fault]. Accelerator sensor 1
Accelerator sensor 2
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit or GND short circuit of sensor 5 V
3. Accelerator 1 sensor failure
4. Accelerator 2 sensor failure
5. E-ECU internal circuit fault

15-34 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the connector pin of the accelerator sensor for deformation and cracks, the condition of
the connection, and whether the retainer is loose or removed.
• Check whether the accelerator sensor wiring is cut or the wiring coating is peeled.

3. Failure diagnosis • Check the accelerator sensor resistance value.

• Check the conduction of the wire harness.
• Check the accelerator sensor output voltage.

86E-7 – 98E-7 Series 15-35

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B1647: —
Failure Failure phenomenon
#B1647 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. (Estimated APS2 terminal voltage - APS2 terminal voltage) is greater than the Wire harness
[Detected value of the dual accelerator sensor fault]. Accelerator sensor 1
Accelerator sensor 2
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit or GND short circuit of sensor 5 V
3. Accelerator 1 sensor failure
4. Accelerator 2 sensor failure
5. E-ECU internal circuit fault

15-36 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the connector pin of the accelerator sensor for deformation and cracks, the condition of
the connection, and whether the retainer is loose or removed.
• Check whether the accelerator sensor wiring is cut or the wiring coating is peeled.

3. Failure diagnosis • Check the accelerator sensor resistance value.

• Check the conduction of the wire harness.
• Check the accelerator sensor output voltage.

86E-7 – 98E-7 Series 15-37

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0228: Accelerrator sensor 3 (Excessive sensor output)

Failure Failure phenomenon
#B0228 Accelerrator sensor 3 (Excessive sensor output)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. Voltage of sensor signal is greater than the threshold value of 4.6 V. Wire harness
Accelerator sensor 3
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit of the sensor GND wire
• Power short circuit of the sensor signal wire
3. Accelerator sensor 3 failure
• Sensor output failure by power short circuit of accelerator sensor 3 internal wiring
4. E-ECU internal circuit fault

15-38 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-14.

2. Connector/wiring check • Before beginning your work, be sure to turn off the power switch.
• Check the connector pin of the accelerator sensor 3 for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the accelerator sensor 3 wiring is cut or the wiring coating is peeled.

3. Failure diagnosis • Check the accelerator sensor 3 resistance value.

• Check the conduction of the wire harness.
• Check the accelerator sensor 3 output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-14.

86E-7 – 98E-7 Series 15-39

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0227: Accelerrator sensor 3 (Insufficient sensor output)

Failure Failure phenomenon
#B0227 Accelerrator sensor 3 (Insufficient sensor output)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. Voltage of sensor signal is less than the threshold value of 0.2 V. Wire harness
Accelerator sensor 3
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit or GND short circuit of the accelerator sensor 3 signal wire
• Open circuit or GND short circuit of sensor 5 V
3. Accelerator sensor 3 failure
• Sensor output failure caused by an open circuit or an increase in sliding friction of the accelerator sensor 3
internal wiring
4. E-ECU internal circuit fault

15-40 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-14.

2. Connector/wiring check • Before beginning your work, be sure to turn off the power switch.
• Check the connector pin of the accelerator sensor 3 for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the accelerator sensor 3 wiring is cut or the wiring coating is peeled.

3. Failure diagnosis • Check the accelerator sensor 3 resistance value.

• Check the conduction of the wire harness.
• Check the accelerator sensor 3 output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-14.

86E-7 – 98E-7 Series 15-41

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B1227: —
Failure Failure phenomenon
#B1227 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. TBD. Wire harness
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

 Diagnosis

15-42 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1126: Accelerrator sensor 3 failure (Foot pedal in open position)

Failure Failure phenomenon Accelerrator sensor 3 failure (Foot pedal in open posi-
#B1126
code (DTC) (Display of screen) tion)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. When the APS3 input voltage is 1.1 V or above and the PDLSW terminal is low Wire harness
level (PDLSW terminal: Open setting). Foot pedal
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit or GND short circuit of the foot pedal signal wire
• Open circuit or GND short circuit of sensor 5 V
3. Foot pedal failure
• Sensor output failure caused by an open circuit or an increase in sliding friction of the foot pedal internal wiring
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-43

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

2. Connector/wiring check • Before beginning your work, be sure to turn off the power switch.
• Check the connector pin of the foot pedal for deformation and cracks, the condition of the con-
nection, and whether the retainer is loose or removed.
• Check whether the foot pedal wiring is cut or the wiring coating is peeled.

3. Failure diagnosis • Check the foot pedal resistance value.

• Check the conduction of the wire harness.
• Check the accelerator sensor output voltage.

15-44 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1125: Accelerrator sensor 3 failure (Foot pedal in closed position)

Failure Failure phenomenon Accelerrator sensor 3 failure (Foot pedal in closed posi-
#B1125
code (DTC) (Display of screen) tion)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite.
2. When the APS3 input voltage is 0.65 V or below and the PDLSW terminal is
high level (PDLSW terminal: Open setting).

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

 Diagnosis

86E-7 – 98E-7 Series 15-45

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

■ Intake throttle opening sensor

#B02E9: Intake Throttle Open Position Sens Error (High V)

Failure Failure phenomenon
#B02E9 Intake Throttle Open Position Sens Error (High V)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.8 V. Wire harness
Intake throttle opening sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the intake throttle opening to the default value 100 %.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The air intake throttle is fully opened.
• The KDPF regeneration terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Intake throttle opening sensor fault
4. E-ECU internal circuit fault

15-46 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-18.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the connector pin of the intake throttle opening sensor for deformation and cracks, the
condition of the connection, and whether the retainer is loose or removed.
• Check whether the intake throttle opening sensor wiring is disconnected or the wiring coating is
peeled.

3. Failure diagnosis • Check the intake throttle opening sensor resistance value.
• Check the conduction of the wire harness.
• Check the intake throttle opening sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-18.

86E-7 – 98E-7 Series 15-47

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B02E8: Intake Throttle Open Position Sens Error (Low V)

Failure Failure phenomenon
#B02E8 Intake Throttle Open Position Sens Error (Low V)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.2 V. Wire harness
Intake throttle opening sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the intake throttle opening to the default value 100 %.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The air intake throttle is fully opened.
• The KDPF regeneration terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Intake throttle opening sensor fault
4. E-ECU internal circuit fault

15-48 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-18.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the connector pin of the intake throttle opening sensor for deformation and cracks, the
condition of the connection, and whether the retainer is loose or removed.
• Check whether the intake throttle opening sensor wiring is disconnected or the wiring coating is
peeled.

3. Failure diagnosis • Check the intake throttle opening sensor resistance value.
• Check the conduction of the wire harness.
• Check the intake throttle opening sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-18.

86E-7 – 98E-7 Series 15-49

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

■ EGR low pressure side sensor

#B0238: EGR Low Pressure Side Sensor Error (High Voltage)

Failure Failure phenomenon
#B0238 EGR Low Pressure Side Sensor Error (High Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.8 V. Wire harness
EGR pressure sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the EGR low pressure side pressure to the default value 900
hPa.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• The calculation by KDPF differential pressure on PM deposit amount terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• GND short circuit of the sensor signal wire
3. EGR pressure sensor failure
• Sensor output failure caused by a GND short circuit of the EGR pressure sensor internal wiring
4. E-ECU internal circuit fault

15-50 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-21.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the EGR pressure sensor for deformation and cracks, the condition of the con-
nection, and whether the retainer is removed.
• Check whether the EGR pressure sensor wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the EGR pressure sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-21.

86E-7 – 98E-7 Series 15-51

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0237: EGR Low Pressure Side Sensor Error (Low Voltage)

Failure Failure phenomenon
#B0237 EGR Low Pressure Side Sensor Error (Low Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.2 V. Wire harness
EGR pressure sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the EGR low pressure side to the default value 900 hPa.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• The calculation by KDPF differential pressure on PM deposit amount terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. EGR pressure sensor failure
4. E-ECU internal circuit fault

15-52 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-21.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the EGR pressure sensor for deformation and cracks, the condition of the con-
nection, and whether the retainer is removed.
• Check whether the EGR pressure sensor wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the EGR pressure sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-21.

86E-7 – 98E-7 Series 15-53

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0236: EGR Low Pres Side Sens Error (Abnorm Learn Value)
Failure Failure phenomenon
#B0236 EGR Low Pres Side Sens Error (Abnorm Learn Value)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. • Before engine startup is completed.
• Atmospheric pressure sensor voltage is normal.
• EGR low-pressure side sensor voltage is normal.
• Atmospheric pressure characteristics do not fall into problem.
* The above conditions are prerequisites for the calculation of the final offset
value of intake manifold pressure.
2. The final offset value of the intake manifold pressure is less than the threshold
value. Or, the final offset value of the intake manifold pressure is greater than
the threshold value.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• The calculation by KDPF differential pressure on PM deposit amount terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. EGR pressure sensor failure
4. E-ECU internal circuit fault

15-54 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-21.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the EGR pressure sensor for deformation and cracks, the condition of the con-
nection, and whether the retainer is removed.
• Check whether the EGR pressure sensor wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the EGR pressure sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-21.

86E-7 – 98E-7 Series 15-55

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

■ EGR high pressure side sensor

#B0473: EGR High Pressure Side Sensor Error (High Voltage)

Failure Failure phenomenon
#B0473 EGR High Pressure Side Sensor Error (High Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.8 V. Wire harness
EGR pressure sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the EGR high pressure side pressure to the default value 900
hPa.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. EGR pressure sensor failure
4. E-ECU internal circuit fault

15-56 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-24.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the EGR pressure sensor for deformation and cracks, the condition of the con-
nection, and whether the retainer is removed.
• Check whether the EGR pressure sensor wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the EGR pressure sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-24.

86E-7 – 98E-7 Series 15-57

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0472: EGR High Pressure Side Sensor Error (Low Voltage)

Failure Failure phenomenon
#B0472 EGR High Pressure Side Sensor Error (Low Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.2 V. Wire harness
EGR pressure sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the EGR high pressure side pressure to the default value 900
hPa.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. EGR pressure sensor failure
4. E-ECU internal circuit fault

15-58 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-24.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the EGR pressure sensor for deformation and cracks, the condition of the con-
nection, and whether the retainer is removed.
• Check whether the EGR pressure sensor wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the EGR pressure sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-24.

86E-7 – 98E-7 Series 15-59

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0471: EGR High Pres Side Sens Error (Abnorm Learn Value)
Failure Failure phenomenon
#B0471 EGR High Pres Side Sens Error (Abnorm Learn Value)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. • Before engine startup is completed.
• Atmospheric pressure sensor voltage is normal.
• EGR low-pressure side sensor voltage is normal.
• Atmospheric pressure characteristics do not fall into problem.
* The above conditions are prerequisites for the calculation of the final offset
value of intake manifold pressure.
2. The final offset value of the exhaust manifold pressure is less than the thresh-
old value. Or, the final offset value of the exhaust manifold pressure is greater
than the threshold value.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. EGR pressure sensor failure
4. E-ECU internal circuit fault

15-60 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-24.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the EGR pressure sensor for deformation and cracks, the condition of the con-
nection, and whether the retainer is removed.
• Check whether the EGR pressure sensor wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the EGR pressure sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-24.

86E-7 – 98E-7 Series 15-61

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

■ Cooling water temperature sensor

#B0118: Cooling Water Temperature Sens Error (High Volt)

Failure Failure phenomenon
#B0118 Cooling Water Temperature Sens Error (High Volt)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.8 V. Wire harness
Cooling water temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the cooling water temperature to the default value of 50 °C (-15
°C at engine start).
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit or power short circuit of the sensor GND wire
• Open circuit or power short circuit of the sensor signal wire
3. Cooling water temperature sensor fault
• Sensor output failure caused by an open circuit of the cooling water temperature sensor internal wiring
4. E-ECU internal circuit fault

15-62 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-27.

2. Connector/wiring check • Before beginning your work, turn off the ECU power.
• Check the pin of the cooling water temperature sensor for deformation and cracks, the condi-
tion of the connection, and whether the retainer is loose or removed.
• Check whether the cooling water temperature sensor wiring is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the cooling water temperature sensor resistance value.
• Check the conduction of the wire harness.
• Check the cooling water temperature sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-27.

86E-7 – 98E-7 Series 15-63

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0117: Cooling Water Temperature Sensor Error (Low Volt)

Failure Failure phenomenon
#B0117 Cooling Water Temperature Sensor Error (Low Volt)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.2 V. Wire harness
Cooling water temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the cooling water temperature to the default value of 50 °C (-15
°C at engine start).
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• GND short circuit of the sensor signal wire
3. Cooling water temperature sensor fault
• Sensor output failure caused by a GND short circuit of the cooling water temperature sensor internal wiring
4. E-ECU internal circuit fault

15-64 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-27.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the cooling water temperature sensor for deformation and cracks, the condi-
tion of the connection, and whether the retainer is loose or removed.
• Check whether the cooling water temperature sensor wiring is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the cooling water temperature sensor resistance value.
• Check the conduction of the wire harness.
• Check the cooling water temperature sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-27.

86E-7 – 98E-7 Series 15-65

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0217: —
Failure Failure phenomenon
#B0217 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The cooling water temperature sensor is normal, and 60 sec have passed Engine cooling water level
since completion of the engine start. Engine cooling equipment
2. Cooling water temperature 110 °C or above is continued for 20 sec. Cooling water temperature sensor system

 Actions when a malfunction occurs

Settings of the actions during a “cooling water temperature high” alarm
No Yes
Fault mode [Continuous operation]: [Limited operation]:
The engine continues to operate without limitations The engine operation is limited.
after the malfunction is detected.
Limited operation No Yes: • The high idle speed or the maximum injection
quantity is limited. (Actions differ by the cus-
tomer setting.)
• The EGR is fully closed.
Reset criteria Yes: • The fault mode is released when the ECU Yes: • The fault mode is released when the ECU
power off is detected. power off is detected.
• Automatic recovery is made when the cooling • Automatic recovery is made when the cooling
water temperature 105 °C or below. water temperature 105 °C or below continues
for 60 sec.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Engine overheat
2. Insufficient engine cooling water
3. Engine cooling equipment fault
4. Cooling water temperature sensor system fault

15-66 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-27.

2. Engine check • Turn off the ECU power and stop the engine.
• Check the engine cooling equipment.
• After a few moments, turn on the ECU power and check whether DTC is detected.

3. Failure diagnosis • Check the cooling water temperature sensor system.

 For details on the diagnosis method and procedure, see Chapter 16 P16-27.

86E-7 – 98E-7 Series 15-67

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

■ New air temperature sensor

#B0113: New Air Temperature Sensor Error (High Voltage)

Failure Failure phenomenon
#B0113 New Air Temperature Sensor Error (High Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.85 V. Wire harness
New air temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the new air temperature to the default value 25 °C.
Limited operation Yes: The reset of ash accumulation value is prohibited.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit or power short circuit of the sensor GND wire
• Open circuit or power short circuit of the sensor signal wire
3. New air temperature sensor fault
• Sensor output failure caused by an open circuit of the new air temperature sensor internal wiring
4. E-ECU internal circuit fault

15-68 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-31.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the new air temperature sensor for deformation and cracks, the condition of
the connection, and whether the retainer is loose or removed.
• Check whether the new air temperature sensor wiring is disconnected or the wiring coating is
peeled.

3. Failure diagnosis • Check the resistance value of the new air temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the new air temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 page P16-31.

86E-7 – 98E-7 Series 15-69

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0112: New Air Temperature Sensor Error (Low Voltage)

Failure Failure phenomenon
#B0112 New Air Temperature Sensor Error (Low Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.15 V. Wire harness
New air temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the new air temperature to the default value 25 °C.
Limited operation Yes: The reset of ash accumulation value is prohibited.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• GND short circuit of the sensor signal wire
3. New air temperature sensor fault
• Sensor output failure caused by a GND short circuit of the new air temperature sensor internal wiring
4. E-ECU internal circuit fault

15-70 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-31.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the new air temperature sensor for deformation and cracks, the condition of
the connection, and whether the retainer is loose or removed.
• Check whether the new air temperature sensor wiring is disconnected or the wiring coating is
peeled.

3. Failure diagnosis • Check the resistance value of the new air temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the new air temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-31.

86E-7 – 98E-7 Series 15-71

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

■ Fuel temperature sensor

#B0183: Fuel Temperature Sensor Error (High Voltage)

Failure Failure phenomenon
#B0183 Fuel Temperature Sensor Error (High Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.8 V. Wire harness
Fuel temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the fuel temperature to the default value 40 °C.
Limited operation Yes: • The reset of ash accumulation value is prohibited.
• Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit or power short circuit of the sensor GND wire
• Open circuit or power short circuit of the sensor signal wire
3. Fuel temperature sensor fault
• Sensor output failure caused by an open circuit of the fuel temperature sensor internal wiring
4. E-ECU internal circuit fault

15-72 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-35.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the fuel temperature sensor for deformation and cracks, the condition of the
connection, and whether the retainer is loose or removed.
• Check whether the fuel temperature sensor wiring is disconnected or the wiring coating is
peeled.

3. Failure diagnosis • Check the resistance value of the fuel temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the fuel temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-35.

86E-7 – 98E-7 Series 15-73

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0182: Fuel Temperature Sensor Error (Low Voltage)

Failure Failure phenomenon
#B0182 Fuel Temperature Sensor Error (Low Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.2 V. Wire harness
Fuel temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the fuel temperature to the default value 40 °C.
Limited operation Yes: • The reset of ash accumulation value is prohibited.
• Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• GND short circuit of the sensor signal wire
3. Fuel temperature sensor fault
• Sensor output failure caused by a GND short circuit of the fuel temperature sensor internal wiring
4. E-ECU internal circuit fault

15-74 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-35.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the fuel temperature sensor for deformation and cracks, the condition of the
connection, and whether the retainer is loose or removed.
• Check whether the fuel temperature sensor wiring is disconnected or the wiring coating is
peeled.

3. Failure diagnosis • Check the resistance value of the fuel temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the fuel temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-35.

86E-7 – 98E-7 Series 15-75

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0168: Fuel Temperature Sensor Temperature Abnormal High

Failure Failure phenomenon
#B0168 Fuel Temperature Sensor Temperature Abnormal High
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Fuel temperature sensor system
2. The engine start is complete and the fuel temperature is continuously 90 °C or Fuel tank
more for a given length of time. Fuel cooler

 Actions when a malfunction occurs

Settings of the actions during a “fuel temperature high” alarm
No Yes
Fault mode [Continuous operation]: [Limited operation]:
The engine continues to operate without limitations The engine operation is limited.
after the malfunction is detected.
Limited operation No Yes: The high idle speed or the engine output maxi-
mum injection quantity is limited. (Actions differ
by the customer setting.)
Reset criteria Yes: • The fault mode is released when the ECU Yes: • The fault mode is released when the ECU
power off is detected. power off is detected.
• Or automatic recovery is made when the fuel • Or automatic recovery is made when the fuel
temperature alarm temperature 80 °C or temperature alarm temperature 80 °C or
below. below continues for a given period of time.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Insufficient fuel in the fuel tank
2. Cooling not possible due to a clogged fuel cooler
3. Fuel temperature sensor system fault

15-76 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-35.

2. Engine check • Turn off the ECU power and stop the engine.
• Check the engine fuel system.
• After a few moments, turn on the ECU power and check whether DTC is detected.

3. Failure diagnosis • Check the fuel temperature sensor system.

 For details on the diagnosis method and procedure, see Chapter 16 P16-35.

86E-7 – 98E-7 Series 15-77

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

■ Rail pressure sensor

#B0193: Rail Pressure Sensor Error (High Voltage)

Failure Failure phenomenon
#B0193 Rail Pressure Sensor Error (High Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.75 V. Wire harness
Rail pressure sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the rail pressure to the default value of 160 MPa.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The rail pressure back-up control functions.
• The KDPF regeneration terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Rail pressure sensor failure
4. E-ECU internal circuit fault

15-78 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-39.

2. Connector/wiring check • Before beginning your work, be sure to turn off the key switch.
• Check the pin of the rail pressure sensor for deformation and cracks, the condition of the con-
nection, and whether the retainer is removed.
• Check whether the rail pressure sensor wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the E-ECU output voltage.
• Check the rail pressure sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-39.

86E-7 – 98E-7 Series 15-79

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B0192: Rail Pressure Sensor Error (Low Voltage)

Failure Failure phenomenon
#B0192 Rail Pressure Sensor Error (Low Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.24 V. Wire harness
Rail pressure sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the rail pressure to the default value of 160 MPa.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The rail pressure back-up control functions.
• The KDPF regeneration terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Rail pressure sensor failure
4. E-ECU internal circuit fault

15-80 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-39.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the rail pressure sensor for deformation and cracks, the condition of the con-
nection, and whether the retainer is removed.
• Check whether the rail pressure sensor wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the E-ECU output voltage.
• Check the rail pressure sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-39.

86E-7 – 98E-7 Series 15-81

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

■ KDPF differential pressure sensor

#B2455: KDPF Differential Pressure Sens Error (High Volt)

Failure Failure phenomenon
#B2455 KDPF Differential Pressure Sens Error (High Volt)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.8 V. Wire harness
KDPF differential pressure sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the KDPF differential pressure to the default value 0 hPa.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• The calculation by KDPF differential pressure on PM deposit amount terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. KDPF differential pressure sensor failure
4. E-ECU internal circuit fault

15-82 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-42.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the KDPF differential pressure sensor for deformation and cracks, the condi-
tion of the connection, and whether the retainer is loose or removed.
• Check whether the KDPF differential pressure sensor wiring is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the resistance value of the KDPF differential pressure sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the KDPF differential pressure sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-42.

86E-7 – 98E-7 Series 15-83

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B2454: KDPF Differential Pressure Sens Error (Low Volt)

Failure Failure phenomenon
#B2454 KDPF Differential Pressure Sens Error (Low Volt)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.2 V. Wire harness
KDPF differential pressure sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the KDPF differential pressure to the default value 0 hPa.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• The calculation by KDPF differential pressure on PM deposit amount terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. KDPF differential pressure sensor failure
4. E-ECU internal circuit fault

15-84 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-42.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the KDPF differential pressure sensor for deformation and cracks, the condi-
tion of the connection, and whether the retainer is loose or removed.
• Check whether the KDPF differential pressure sensor wiring is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the resistance value of the KDPF differential pressure sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the KDPF differential pressure sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-42.

86E-7 – 98E-7 Series 15-85

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B2452: KDPF Differential Pressure High Error

Failure Failure phenomenon
#B2452 KDPF Differential Pressure High Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. After the completion of startup.
2. KDPF differential pressure is 50 kPa or more for a given period of time (15 s)
after the completion of the engine start.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. KDPF differential pressure sensor failure
4. E-ECU internal circuit fault

15-86 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-42.

2. Connector/wiring check • Before beginning your work, be sure to turn off the key switch.
• Check the pin of the KDPF differential pressure sensor for deformation and cracks, the condi-
tion of the connection, and whether the retainer is loose or removed.
• Check whether the KDPF differential pressure sensor wiring is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the output voltage of the KDPF differential pressure sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-42.

86E-7 – 98E-7 Series 15-87

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B2453: KDPF Different Press Sens (Abnormal Learn Value)

Failure Failure phenomenon
#B2453 KDPF Different Press Sens (Abnormal Learn Value)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. • Before engine startup is completed.
• KDPF differential pressure sensor voltage is normal.
* The above conditions are prerequisites for the calculation of the offset value
of KDPF differential pressure.
2. The final KDPF differential pressure offset value is less than the threshold
value of 380 hPa. Or, the final KDPF differential pressure offset value is
greater than the threshold value of 500 hPa.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• The calculation by KDPF differential pressure on PM deposit amount terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. EGR pressure sensor failure
4. E-ECU internal circuit fault

15-88 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-42.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the KDPF differential pressure sensor for deformation and cracks, the condi-
tion of the connection, and whether the retainer is loose or removed.
• Check whether the KDPF differential pressure sensor wiring is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the output voltage of the KDPF differential pressure sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-42.

86E-7 – 98E-7 Series 15-89

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

■ KDPF high pressure side sensor

#B1455: KDPF High Pressure Side Sens Error (High Volt)

Failure Failure phenomenon
#B1455 KDPF High Pressure Side Sens Error (High Volt)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.8 V. Wire harness
KDPF high pressure side sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the KDPF high pressure side pressure to the default value 900
hPa.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• The calculation by KDPF differential pressure on PM deposit amount terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. KDPF high pressure side sensor failure
4. E-ECU internal circuit fault

15-90 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-42.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the KDPF high pressure side sensor for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the KDPF high pressure side sensor wiring is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the resistance value of the KDPF high pressure side sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the KDPF high pressure side sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-42.

86E-7 – 98E-7 Series 15-91

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B1454: KDPF High Pressure Side Sensor Error (Low Voltage)

Failure Failure phenomenon
#B1454 KDPF High Pressure Side Sensor Error (Low Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.2 V. Wire harness
KDPF high pressure side sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the KDPF high pressure side pressure to the default value 900
hPa.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• The calculation by KDPF differential pressure on PM deposit amount terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. KDPF high pressure side sensor failure
4. E-ECU internal circuit fault

15-92 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-42.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the KDPF high pressure side sensor for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the KDPF high pressure side sensor wiring is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the resistance value of the KDPF high pressure side sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the KDPF high pressure side sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-42.

86E-7 – 98E-7 Series 15-93

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

■ KDPF inlet temperature sensor

#B1428: KDPF Inlet Temperature Sensor Error (High Voltage)

Failure Failure phenomenon
#B1428 KDPF Inlet Temperature Sensor Error (High Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.8 V. Wire harness
KDPF inlet temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the KDPF inlet temperature to the default value 350 °C.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit or power short circuit of the sensor GND wire
• Open circuit or power short circuit of the sensor signal wire
3. KDPF inlet temperature sensor fault
• Sensor output failure caused by an open circuit of the KDPF inlet temperature sensor internal wiring
4. E-ECU internal circuit fault

15-94 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-46.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the KDPF inlet temperature sensor for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the KDPF inlet temperature sensor wiring is disconnected or the wiring coating
is peeled.

3. Failure diagnosis • Check the resistance value of the KDPF inlet temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the KDPF inlet temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-46.

86E-7 – 98E-7 Series 15-95

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B1427: KDPF Inlet Temperature Sensor Error (Low Voltage)

Failure Failure phenomenon
#B1427 KDPF Inlet Temperature Sensor Error (Low Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.2 V. Wire harness
KDPF inlet temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the KDPF inlet temperature to the default value 350 °C.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• GND short circuit of the sensor signal wire
3. KDPF inlet temperature sensor fault
• Sensor output failure caused by a GND short circuit of the KDPF inlet temperature sensor internal wiring
4. E-ECU internal circuit fault

15-96 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-46.

2. Connector/wiring check • Before beginning your work, turn off the ECU power.
• Check the pin of the KDPF inlet temperature sensor for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the KDPF inlet temperature sensor wiring is disconnected or the wiring coating
is peeled.

3. Failure diagnosis • Check the resistance value of the KDPF inlet temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the KDPF inlet temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-46.

86E-7 – 98E-7 Series 15-97

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B1436: KDPF Inlet Temperature High Error

Failure Failure phenomenon
#B1436 KDPF Inlet Temperature High Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. KDPF inlet temperature sensor normal Connector
2. The KDPF inlet temperature is 700 °C or more for a given period of time (15 s). Wire harness
KDPF inlet temperature sensor
E-ECU
Injector
Exhaust piping

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. KDPF inlet temperature sensor system fault
4. E-ECU internal circuit fault
5. Blow by combustion gas
• Piping damage in the passage to KDOC
6. Injector defect
• Decrease in injection quantity
• Injection timing malfunction

15-98 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ KDPF intermediate temperature sensor

#B1434: KDPF Intermediate Temperature Sens Error (HighVolt)

Failure Failure phenomenon
#B1434 KDPF Intermediate Temperature Sens Error (HighVolt)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.8 V. Wire harness
KDPF intermediate temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the KDPF intermediate temperature to the default value 350 °C.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• The calculation by KDPF differential pressure on PM deposit amount terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit or power short circuit of the sensor GND wire
• Open circuit or power short circuit of the sensor signal wire
3. KDPF intermediate temperature sensor fault
• Sensor output failure caused by an open circuit of the KDPF intermediate temperature sensor internal wiring
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-99

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-50.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the KDPF intermediate temperature sensor for deformation and cracks, the
condition of the connection, and whether the retainer is loose or removed.
• Check whether the KDPF intermediate temperature sensor wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the resistance value of the KDPF intermediate temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the KDPF intermediate temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-50.

15-100 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1435: KDPF Intermediate Temperature Sens Error (LowVolt)

Failure Failure phenomenon
#B1435 KDPF Intermediate Temperature Sens Error (LowVolt)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.2 V. Wire harness
KDPF intermediate temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the KDPF intermediate temperature to the default value 350 °C.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• The calculation by KDPF differential pressure on PM deposit amount terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• GND short circuit of the sensor signal wire
3. KDPF intermediate temperature sensor fault
• Sensor output failure caused by a GND short circuit of the KDPF intermediate temperature sensor internal wir-
ing
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-101

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-50.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the KDPF intermediate temperature sensor for deformation and cracks, the
condition of the connection, and whether the retainer is loose or removed.
• Check whether the KDPF intermediate temperature sensor wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the resistance value of the KDPF intermediate temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the KDPF intermediate temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-50.

15-102 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0420: KDPF Inter Temperature Low Error

Failure Failure phenomenon
#B0420 KDPF Inter Temperature Low Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. KDPF regeneration defect timer is more than the constant value (1200 s). Wire harness
KDPF intermediate temperature sensor sys-
tem
E-ECU
Injector
KDOC
Piping

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. KDPF intermediate temperature sensor system fault
4. E-ECU internal circuit fault
5. KDOC deterioration due to the external factor such as sulfur poisoning
• Increase in activated temperature
6. Blow by combustion gas
• Catalytic damage
• Piping damage in the passage to KDOC
7. Injector defect
• Decrease in injection quantity
• Injection timing malfunction

86E-7 – 98E-7 Series 15-103

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B1426: KDPF InterTemperature High Error (Post-injection)

Failure Failure phenomenon
#B1426 KDPF InterTemperature High Error (Post-injection)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Regeneration is active.
2. The KDPF intermediate temperature 700 deg. or more is continued for a given
period of time (30 s).

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. KDPF intermediate temperature sensor system fault
4. E-ECU internal circuit fault
5. Injector defect
• Increase in injection quantity
• Injection timing malfunction

15-104 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ Atmospheric pressure sensor

#B2229: Ambient Pressure Sensor Error (High Voltage)

Failure Failure phenomenon
#B2229 Ambient Pressure Sensor Error (High Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Atmospheric pressure sensor
2. The sensor voltage is above 4.8 V. E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the atmospheric pressure to the default value 900 hPa.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. E-ECU internal atmospheric pressure sensor fault
2. E-ECU internal circuit fault

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.

 For details on the diagnosis method and procedure, see Chapter 16 P16-107.

86E-7 – 98E-7 Series 15-105

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

#B2228: Ambient Pressure Sensor Error (Low Voltage)

Failure Failure phenomenon
#B2228 Ambient Pressure Sensor Error (Low Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Atmospheric pressure sensor
2. The sensor voltage is below 0.2 V. E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the atmospheric pressure to the default value 900 hPa.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. E-ECU internal atmospheric pressure sensor fault
2. E-ECU internal circuit fault

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.

 For details on the diagnosis method and procedure, see Chapter 16 P16-107.

15-106 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1231: Ambient Pressure Sensor Characteristic Error

Failure Failure phenomenon
#B1231 Ambient Pressure Sensor Characteristic Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Atmospheric pressure sensor
2. The intake manifold pressure final offset quantity 5 kPa or more and the E-ECU
exhaust manifold pressure final offset quantity 5 kPa or more continue for 600
ms.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. E-ECU internal atmospheric pressure sensor fault
2. E-ECU internal circuit fault
3.  Simultaneous characteristic malfunction of EGR high pressure side sensor and low pressure side sensor
4. Blockage or icing caused by foreign matters in the sensor parts

 This error can be detected by the simultaneous characteristic malfunction of EGR high pressure side sensor and
low pressure side sensor. However, the possibility of the occurrence of the characteristic malfunction at the same time
is low. So, if the error is not released after replacing the ECU, perform failure diagnosis on EGR high pressure side
sensor and EGR low pressure side sensor, respectively.

86E-7 – 98E-7 Series 15-107

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.

 For details on the diagnosis method and procedure, see Chapter 16 P16-107.

2. Diagnosis for EGR high • Check the sensor resistance value.

pressure side sensor and • Check the conduction of the wire harness.
low pressure side sensor • Check the sensor output voltage.

 For details on the diagnosis method and procedure, see Chapter 16 P16-107.

15-108 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ EGR gas temperature sensor

#B041D: EGR Gas Temperature Sensor Error (High Voltage)

Failure Failure phenomenon
#B041D EGR Gas Temperature Sensor Error (High Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.8 V. Wire harness
EGR gas temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the EGR gas temperature to the default value 30 °C.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. EGR gas temperature sensor fault
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-109

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-54.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the EGR gas temperature sensor for deformation and cracks, the condition of
the connection, and whether the retainer is loose or removed.
• Check whether the EGR gas temperature sensor wiring is disconnected or the wiring coating is
peeled.

3. Failure diagnosis • Check the resistance value of the EGR gas temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the EGR gas temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-54.

15-110 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B041C: EGR Gas Temperature Sensor Error (Low Voltage)

Failure Failure phenomenon
#B041C EGR Gas Temperature Sensor Error (Low Voltage)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.2 V. Wire harness
EGR gas temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the EGR gas temperature to the default value 30 °C.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. EGR gas temperature sensor fault
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-111

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-54.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the EGR gas temperature sensor for deformation and cracks, the condition of
the connection, and whether the retainer is loose or removed.
• Check whether the EGR gas temperature sensor wiring is disconnected or the wiring coating is
peeled.

3. Failure diagnosis • Check the resistance value of the EGR gas temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the EGR gas temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-54.

15-112 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ Intake manifold temperature sensor

#B040D: Intake Manifold Temperature Sens Error (High Volt)

Failure Failure phenomenon
#B040D Intake Manifold Temperature Sens Error (High Volt)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.8 V. Wire harness
Intake manifold temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the intake air temperature to the default value 100 °C (200 °C in
the case with turbocharger).
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The air Intake throttle is fully opened.
• The KDPF regeneration terminates.
• The calculation by KDPF differential pressure on PM deposit amount terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Intake manifold temperature sensor fault
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-113

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-58.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the intake manifold temperature sensor for deformation and cracks, the condi-
tion of the connection, and whether the retainer is loose or removed.
• Check whether the intake manifold temperature sensor wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the resistance value of the intake manifold temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the intake manifold temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-58.

15-114 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B040C: Intake Manifold Temperature Sens Error (Low Volt)

Failure Failure phenomenon
#B040C Intake Manifold Temperature Sens Error (Low Volt)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.2 V. Wire harness
Intake manifold temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the intake air temperature to the default value 100 °C (200 °C in
the case with turbocharger).
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The air Intake throttle is fully opened.
• The KDPF regeneration terminates.
• The calculation by KDPF differential pressure on PM deposit amount terminates.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Intake manifold temperature sensor fault
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-115

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-58.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the intake manifold temperature sensor for deformation and cracks, the condi-
tion of the connection, and whether the retainer is loose or removed.
• Check whether the intake manifold temperature sensor wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the resistance value of the intake manifold temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the intake manifold temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-58.

15-116 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ Exhaust manifold temperature sensor

#B0546: Exhaust Manifold Temperature Sens Error (HighVolt)

Failure Failure phenomenon
#B0546 Exhaust Manifold Temperature Sens Error (HighVolt)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is above 4.8 V. Wire harness
Exhaust manifold temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the exhaust temperature to the default value of 550 °C.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Exhaust manifold temperature sensor fault
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-117

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-62.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the exhaust manifold temperature sensor for deformation and cracks, the con-
dition of the connection, and whether the retainer is loose or removed.
• Check whether the exhaust manifold temperature sensor wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the resistance value of the exhaust manifold temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the exhaust manifold temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-62.

15-118 86E-7 – 98E-7 Series

Sensor related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0545: Exhaust Manifold Temperature Sens Error (Low Volt)

Failure Failure phenomenon
#B0545 Exhaust Manifold Temperature Sens Error (Low Volt)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No judgment is made during the engine start recognition. Connector
2. The sensor voltage is below 0.2 V. Wire harness
Exhaust manifold temperature sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited by setting the exhaust temperature to the default value of 550 °C.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The reset of ash accumulation value is prohibited.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Exhaust manifold temperature sensor fault
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-119

FAILURE CODE (DTC) GENERAL DESCRIPTION Sensor related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the sensor voltage value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-62.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the exhaust manifold temperature sensor for deformation and cracks, the con-
dition of the connection, and whether the retainer is loose or removed.
• Check whether the exhaust manifold temperature sensor wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the resistance value of the exhaust manifold temperature sensor.
• Check the conduction of the wire harness.
• Check the output voltage of the exhaust manifold temperature sensor.

 For details on the diagnosis method and procedure, see Chapter 16 P16-62.

15-120 86E-7 – 98E-7 Series

Contact output related FAILURE CODE (DTC) GENERAL DESCRIPTION

Contact output related

■ Main relay

#B068B: Main Relay Contact Stuck

Failure Failure phenomenon
#B068B Main Relay Contact Stuck
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. A judgment is made when the ECU is shut off. Connector
2. The main relay does not open after the elapse of 150 ms at the time of shutting Wire harness
off the ECU. Main relay
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• GND short circuit of the main relay coil side downstream wire
3. Main relay contact fault
• Main relay contact stuck
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-121

FAILURE CODE (DTC) GENERAL DESCRIPTION Contact output related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check whether you can log in to the SMARTASSIST-DIRECT after turning off the power switch
and the elapse of a given period of time.

 For details on the diagnosis method and procedure, see Chapter 16 P16-66.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the main relay connector for deformation and cracks, the condition of the con-
nection, and whether the retainer is loose or removed.
• Check whether the main relay wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the main relay contact.

• Check the main relay resistance value.
• Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-66.

15-122 86E-7 – 98E-7 Series

Contact output related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B068A: Main Relay Early Opening

Failure Failure phenomenon
#B068A Main Relay Early Opening
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Judgment is made when the ECU is initialized. Connector
2. ECU power shutdown without performing the after run (EEPROM write pro- Wire harness
cess after turning off the key switch). Main relay
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• GND short circuit of the main relay coil side downstream wire
3. Main relay contact fault
• Main relay contact stuck
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-123

FAILURE CODE (DTC) GENERAL DESCRIPTION Contact output related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-66.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the main relay connector for deformation and cracks, the condition of the con-
nection, and whether the retainer is loose or removed.
• Check whether the main relay wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the main relay contact.

• Check the main relay resistance value.
• Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-66.

15-124 86E-7 – 98E-7 Series

Contact output related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ Startup assist relay

#B0543: Startup Assist Relay Open Circuit

Failure Failure phenomenon
#B0543 Startup Assist Relay Open Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Current is OFF in the startup assist relay. Connector
2. IC open circuit inside the ECU is detected. Wire harness
Startup assist relay
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Open circuit of startup assist relay power
• Power short circuit of startup assist relay power
3. Startup assist relay fault
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-125

FAILURE CODE (DTC) GENERAL DESCRIPTION Contact output related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-70.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the startup assist relay for deformation and cracks, the condition of the con-
nection, and whether the retainer is loose or removed.
• Check whether the startup assist relay wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the startup assist relay resistance value.

• Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-70.

15-126 86E-7 – 98E-7 Series

Contact output related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0541: Startup Assist Relay GND Short Circuit

Failure Failure phenomenon
#B0541 Startup Assist Relay GND Short Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Current is OFF in the startup assist relay. Connector
2. IC open circuit inside the ECU is detected. Wire harness
Startup assist relay
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• GND short circuit of startup assist relay power
3. Startup assist relay fault
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-127

FAILURE CODE (DTC) GENERAL DESCRIPTION Contact output related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-70.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the startup assist relay for deformation and cracks, the condition of the con-
nection, and whether the retainer is loose or removed.
• Check whether the startup assist relay wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the startup assist relay resistance value.

• Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-70.

15-128 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

CRS (common rail system) related

■ Injector 4

#B0204 (4-cylinder engine): Injector of 4th Cylinder OpenC (Inherent Location)

#B0203 (3-cylinder engine): —
#B0204
Injector of 4th Cylinder OpenC (Inherent Location)
Failure (4-cylinder engine) Failure phenomenon
code (DTC) #B0203 (Display of screen)
—
(3-cylinder engine)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. In the drive circuit, the detection is made as an open circuit of the high side or Wire harness
low side. E-ECU
Injector

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The fuel injection of failed cylinder terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Injector drive system open circuit
3. E-ECU internal circuit fault
4. Open circuit of the injector internal circuit

86E-7 – 98E-7 Series 15-129

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

15-130 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0271 (4-cylinder engine): Injector of 4th Cylinder Coil Short Circuit

#B0268 (3-cylinder engine): —
#B0271
Injector of 4th Cylinder Coil Short Circuit
Failure (4-cylinder engine) Failure phenomenon
code (DTC) #B0268 (Display of screen)
—
(3-cylinder engine)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. In the injector coil, the detection is made as a short circuit of the high side and Wire harness
low side. E-ECU
Injector

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The fuel injection of failed cylinder terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Injector drive system short circuit
3. E-ECU internal circuit fault
4. Short circuit of the injector internal circuit

86E-7 – 98E-7 Series 15-131

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

15-132 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1271 (4-cylinder engine): Injector of 4th Cylinder Short Circuit

#B1268 (3-cylinder engine): —
#B1271
Injector of 4th Cylinder Short Circuit
Failure (4-cylinder engine) Failure phenomenon
code (DTC) #B1268 (Display of screen)
—
(3-cylinder engine)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. + B short circuit in the low side is detected in the drive circuit. Wire harness
E-ECU
Injector

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The fuel injection of failed cylinder terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Injector drive system short circuit
3. E-ECU internal circuit fault
4. Short circuit of the injector internal circuit

86E-7 – 98E-7 Series 15-133

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-85.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-85.

15-134 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ Injector 2

#B0202: Injector of 2nd Cylinder OpenC (Inherent Location)

Failure Failure phenomenon
#B0202 Injector of 2nd Cylinder OpenC (Inherent Location)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. In the TWV drive circuit, the detection is made as an open circuit of the high Wire harness
side or low side. E-ECU
Injector

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The fuel injection of failed cylinder terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Injector drive system open circuit
3. E-ECU internal circuit fault
4. Open circuit of the injector internal circuit

86E-7 – 98E-7 Series 15-135

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

15-136 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0265: Injector of 2nd Cylinder Coil Short Circuit

Failure Failure phenomenon
#B0265 Injector of 2nd Cylinder Coil Short Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. In the injector coil, the detection is made as a short circuit of the high side and Wire harness
low side. E-ECU
Injector

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The fuel injection of failed cylinder terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Injector drive system short circuit
3. E-ECU internal circuit fault
4. Short circuit of the injector internal circuit

86E-7 – 98E-7 Series 15-137

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

15-138 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1265: Injector of 2nd Cylinder Short Circuit

Failure Failure phenomenon
#B1265 Injector of 2nd Cylinder Short Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. + B short circuit in the low side is detected in the drive circuit. Wire harness
E-ECU
Injector

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The fuel injection of failed cylinder terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Injector drive system short circuit
3. E-ECU internal circuit fault
4. Short circuit of the injector internal circuit

86E-7 – 98E-7 Series 15-139

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-85.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-85.

15-140 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ Injector 1

#B0201: Injector of 1st Cylinder OpenC (Inherent Location)

Failure Failure phenomenon
#B0201 Injector of 1st Cylinder OpenC (Inherent Location)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. In the drive circuit, the detection is made as an open circuit of the high side or Wire harness
low side. E-ECU
Injector

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The fuel injection of failed cylinder terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Injector drive system open circuit
3. E-ECU internal circuit fault
4. Open circuit of the injector internal circuit

86E-7 – 98E-7 Series 15-141

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

15-142 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0262: Injector of 1st Cylinder Coil Short Circuit

Failure Failure phenomenon
#B0262 Injector of 1st Cylinder Coil Short Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. In the injector coil, the detection is made as a short circuit of the high side and Wire harness
low side. E-ECU
Injector

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The fuel injection of failed cylinder terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Injector drive system short circuit
3. E-ECU internal circuit fault
4. Short circuit of the injector internal circuit

86E-7 – 98E-7 Series 15-143

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

15-144 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1262: Injector of 1st Cylinder Short Circuit

Failure Failure phenomenon
#B1262 Injector of 1st Cylinder Short Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. + B short circuit in the low side is detected in the drive circuit. Wire harness
E-ECU
Injector

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The fuel injection of failed cylinder terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Injector drive system short circuit
3. E-ECU internal circuit fault
4. Short circuit of the injector internal circuit

86E-7 – 98E-7 Series 15-145

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-85.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-85.

15-146 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ Injector 3

#B0203 (4-cylinder engine): Injector of 3rd Cylinder OpenC (Inherent Location)

Failure Failure phenomenon
#B0203 Injector of 3rd Cylinder OpenC (Inherent Location)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. In the drive circuit, the detection is made as an open circuit of the high side or Wire harness
low side. E-ECU
Injector

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The fuel injection of failed cylinder terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Injector drive system open circuit
3. E-ECU internal circuit fault
4. Open circuit of the injector internal circuit

86E-7 – 98E-7 Series 15-147

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

15-148 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0268 (4-cylinder engine): Injector of 3rd Cylinder Coil Short Circuit

Failure Failure phenomenon
#B0268 Injector of 3rd Cylinder Coil Short Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. In the injector coil, the detection is made as a short circuit of the high side and Wire harness
low side. E-ECU
Injector

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The fuel injection of failed cylinder terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Injector drive system short circuit
3. E-ECU internal circuit fault
4. Short circuit of the injector internal circuit

86E-7 – 98E-7 Series 15-149

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-81.

15-150 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1268 (4-cylinder engine): Injector of 3rd Cylinder Short Circuit

Failure Failure phenomenon
#B1268 Injector of 3rd Cylinder Short Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. + B short circuit in the low side is detected in the drive circuit. Wire harness
E-ECU
Injector

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The fuel injection of failed cylinder terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Injector drive system short circuit
3. E-ECU internal circuit fault
4. Short circuit of the injector internal circuit

86E-7 – 98E-7 Series 15-151

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-85.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-85.

15-152 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ Injector (common)

#B0611: Injector Drive IC Error

Failure Failure phenomenon
#B0611 Injector Drive IC Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected.
2. ECU detects the drive IC fault.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The failed bank injection terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. E-ECU internal circuit fault

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-153

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

#B1146: Injector Drive Circuit (Bank1) Short Circuit

Failure Failure phenomenon
#B1146 Injector Drive Circuit (Bank1) Short Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. In the drive circuit, the detection is made as a GND short circuit of the high side Wire harness
or low side, or +B short circuit of the high side. Injector
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The failed bank injection terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Power short circuit of the high side of the injector bank1
• GND short circuit of the high side of the injector bank1
• Power short circuit of the low side of the injector bank1
• GND short circuit of the low side of the injector bank1
3. Injector fault by power short circuit
4. E-ECU internal circuit fault

15-154 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-85.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-85.

86E-7 – 98E-7 Series 15-155

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

#B1149: Injector Drive Circuit (Bank2) Short Circuit

Failure Failure phenomenon
#B1149 Injector Drive Circuit (Bank2) Short Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Cam/crank pulse is detected. Connector
2. In the drive circuit, the detection is made as a GND short circuit of the high side Wire harness
or low side, or +B short circuit of the high side. Injector
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The failed bank injection terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Power short circuit of the high side of the injector bank2
• GND short circuit of the high side of the injector bank2
• Power short circuit of the low side of the injector bank2
• GND short circuit of the low side of the injector bank2
3. Injector fault by power short circuit
4. E-ECU internal circuit fault

15-156 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-85.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the injector for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the injector wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the injector resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-85.

86E-7 – 98E-7 Series 15-157

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

#B1648: Injector of 1st Cylinder Compensation Value Error

Failure Failure phenomenon
#B1648 Injector of 1st Cylinder Compensation Value Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During EEPROM initialization or value input. E-ECU
2. The injector corrected value is not or mistakenly entered, and the EEPROM
cannot be read.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Input failure of the injector correction value
2. E-ECU internal circuit fault

 Diagnosis
1. Initial diagnosis with the • Check the fault indication. Input the injector correction value again.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

15-158 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1649: Injector of 2nd Cylinder Compensation Value Error

Failure Failure phenomenon
#B1649 Injector of 2nd Cylinder Compensation Value Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During EEPROM initialization or value input. E-ECU
2. The injector corrected value is not or mistakenly entered, and the EEPROM
cannot be read.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Input failure of the injector correction value
2. E-ECU internal circuit fault

 Diagnosis
1. Initial diagnosis with the • Check the fault indication. Input the injector correction value again.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-159

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

#B1650: Injector of 3rd Cylinder Compensation Value Error

Failure Failure phenomenon
#B1650 Injector of 3rd Cylinder Compensation Value Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During EEPROM initialization or value input. E-ECU
2. The injector corrected value is not or mistakenly entered, and the EEPROM
cannot be read.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Input failure of the injector correction value
2. E-ECU internal circuit fault

 Diagnosis
1. Initial diagnosis with the • Check the fault indication. Input the injector correction value again.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

15-160 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1651: Injector of 4th Cylinder Compensation Value Error

Failure Failure phenomenon
#B1651 Injector of 4th Cylinder Compensation Value Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During EEPROM initialization or value input. E-ECU
2. The injector corrected value is not or mistakenly entered, and the EEPROM
cannot be read.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Input failure of the injector correction value
2. E-ECU internal circuit fault

 Diagnosis
1. Initial diagnosis with the • Check the fault indication. Input the injector correction value again.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-161

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

■ SCV (MPROP)

#B1641: SCV (MPROP) (Low Side VB Short)

Failure Failure phenomenon
#B1641 SCV (MPROP) (Low Side VB Short)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The low side VB short circuit in the high pressure pump drive circuit continues Wire harness
for a given period of time (300 s). Injector
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Power short circuit of the SCV (MPROP) low side
3. SCV (MPROP) fault by the power short circuit
4. E-ECU internal circuit fault

15-162 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1643: SCV (MPROP) (Low Side GND Short)

Failure Failure phenomenon
#B1643 SCV (MPROP) (Low Side GND Short)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. GND short-circuit continues for fixed number of tests (5 times) at a fixed inter- Wire harness
val (1.0 seconds). SCV (MPROP)
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• GND short circuit of the low side wiring of SCV (MPROP)
3. SCV (MPROP) low side GND short circuit
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-163

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-87.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the SCV (MPROP) for deformation and cracks, the condition of the connec-
tion, and whether the retainer is loose or removed.
• Check whether the SCV (MPROP) wiring is shorted to the ground line or the wiring coating is
peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the SCV (MPROP) resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-87.

15-164 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0629: SCV (MPROP) (High Side VB Short)

Failure Failure phenomenon
#B0629 SCV (MPROP) (High Side VB Short)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. VB short-circuit continues for a fixed time (300 ms). Wire harness
SCV (MPROP)
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Power short circuit of SCV (+) output
• Power short circuit of SVC (-) output
3. SCV fault caused by a coil short circuit
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-165

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-87.

2. Connector/wiring check • Before beginning your work, be sure to turn off the power switch.
• Check the pin of the SCV for deformation and cracks, the condition of the connection, and
whether the retainer is loose or removed.
• Check whether the SCV wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the SCV resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-87.

15-166 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1642: SCV (MPROP) (High Side GND Short)

Failure Failure phenomenon
#B1642 SCV (MPROP) (High Side GND Short)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. GND short-circuit continues for fixed number of tests (5 times) at a fixed inter- Wire harness
val (1.0 seconds). SCV (MPROP)
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Power short circuit of the SCV (MPROP) high side
3. SCV (MPROP) fault by the power short circuit
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-167

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

#B0627: SCV (MPROP) (Open Circuit)

Failure Failure phenomenon
#B0627 SCV (MPROP) (Open Circuit)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The high pressure pump drive circuit detects the open circuit. Wire harness
SCV (MPROP)
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• SCV (MPROP) open circuit
3. SCV (MPROP) fault by the open circuit
4. E-ECU internal circuit fault

15-168 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B062A: SCV (MPROP) (Drive Current High Error)

Failure Failure phenomenon
#B062A SCV (MPROP) (Drive Current High Error)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The drive current is greater than threshold value. Wire harness
SCV (MPROP)
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. SCV (MPROP) fault
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-169

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-87.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the SCV (MPROP) for deformation and cracks, the condition of the connec-
tion, and whether the retainer is loose or removed.
• Check whether the SCV (MPROP) wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the SCV (MPROP) resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-87.

15-170 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1645: SCV (MPROP) (Pump Overload Error)

Failure Failure phenomenon
#B1645 SCV (MPROP) (Pump Overload Error)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. Abnormal heating in drive circuit is detected. Wire harness
SCV (MPROP)
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. SCV (MPROP) fault
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-171

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-87.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the SCV (MPROP) for deformation and cracks, the condition of the connec-
tion, and whether the retainer is loose or removed.
• Check whether the SCV (MPROP) wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the SCV (MPROP) resistance value.

 For details on the diagnosis method and procedure, see Chapter 16 P16-87.

15-172 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ Abnormal rail pressure

#B0088: Actual Rail Pressure Rise Error

Failure Failure phenomenon
#B0088 Actual Rail Pressure Rise Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Rail pressure sensor is normal. Fuel system
2. When the specified time (5 s) is continued with the rail pressure 170 MPa or Supply pump
more. Rail pressure sensor

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Rail pressure sensor system failure
2. SCV drive circuit system failure
3. SCV stuck open
4. SCV intermittent fault
5. Fuel system failure
• Air intrusion
• Insufficient gas

86E-7 – 98E-7 Series 15-173

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the SCV (MPROP) and the rail pressure sensor for deformation and cracks,
the condition of the connection, and whether the retainer is loose or removed.
• Check whether the SCV (MPROP) and the rail pressure sensor wiring is disconnected or
shorted to the power/ground line, or the wiring coating is peeled.

3. Failure diagnosis • Check the fuel system, common rail system, and supply pump.
• If needed, exchange the parts of the fuel system or common rail system, supply pump.

 For details on the check method and procedure, refer to "Structure and Function, Testing and
Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-174 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0094: Rail Press Deviation Error in Act Rail Press Drop

Failure Failure phenomenon
#B0094 Rail Press Deviation Error in Act Rail Press Drop
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Rail pressure sensor is normal. Fuel system
2. The actual rail pressure is smaller than the target rail pressure and the differ- Supply pump
ence of 20 MPa or more is continued for a given period of time (3 s). Rail pressure sensor

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Rail pressure sensor system failure
2. SCV drive circuit system failure
3. SCV open sticking
4. SCV closed sticking
5. SCV intermittent fault
6. Fuel system failure
• Air intrusion
• Insufficient gas

86E-7 – 98E-7 Series 15-175

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the SCV (MPROP) and the rail pressure sensor for deformation and cracks,
the condition of the connection, and whether the retainer is loose or removed.
• Check whether the SCV (MPROP) and the rail pressure sensor wiring is disconnected or
shorted to the power/ground line, or the wiring coating is peeled.

3. Failure diagnosis • Check the fuel system, common rail system, and supply pump.
• If needed, exchange the parts of the fuel system or common rail system, supply pump.

 For details on the check method and procedure, refer to "Structure and Function, Testing and
Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-176 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B0093: Rail Press Deviation Error in Act Rail Press Rise

Failure Failure phenomenon
#B0093 Rail Press Deviation Error in Act Rail Press Rise
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Rail pressure sensor is normal. Fuel system
2. The actual rail pressure is larger than the target rail pressure and the differ- Supply pump
ence of 20 MPa or more is continued for a given period of time (5 s). Rail pressure sensor

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Rail pressure sensor system failure
2. SCV drive circuit system failure
3. SCV open sticking
4. SCV intermittent fault
5. Fuel system failure
• Air intrusion
• Insufficient gas

86E-7 – 98E-7 Series 15-177

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the SCV (MPROP) and the rail pressure sensor for deformation and cracks,
the condition of the connection, and whether the retainer is loose or removed.
• Check whether the SCV (MPROP) and the rail pressure sensor wiring is disconnected or
shorted to the power/ground line, or the wiring coating is peeled.

3. Failure diagnosis • Check the fuel system, common rail system, and supply pump.
• If needed, exchange the parts of the fuel system or common rail system, supply pump.

 For details on the check method and procedure, refer to "Structure and Function, Testing and
Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-178 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ PLV (Common rail pressure limit valve)

#B000F: PLV Open Valve

Failure Failure phenomenon
#B000F PLV Open Valve
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Fuel system
2. Common rail pressure limit valve opens. Supply pump

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Rail pressure sensor system failure
2. SCV drive circuit system failure
3. SCV open sticking
4. SCV intermittent fault
5. Fuel system failure
• Air intrusion
• Insufficient gas

86E-7 – 98E-7 Series 15-179

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the SCV (MPROP) and the rail pressure sensor for deformation and cracks,
the condition of the connection, and whether the retainer is loose or removed.
• Check whether the SCV (MPROP) and the rail pressure sensor wiring is disconnected or
shorted to the power/ground line, or the wiring coating is peeled.

3. Failure diagnosis • Check the fuel system, common rail system, and supply pump.
• If needed, exchange the parts of the fuel system or common rail system, supply pump.

 For details on the check method and procedure, refer to "Structure and Function, Testing and
Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-180 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1666: PLV (Number of times of PLV Valve Opening Error)

Failure Failure phenomenon
#B1666 PLV (Number of times of PLV Valve Opening Error)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Rail pressure sensor is normal. Fuel system
2. The opening times of the pressure control valve of common rail exceeds 50. Supply pump
Rail pressure sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Rail pressure sensor system failure
2. SCV drive circuit system failure
3. SCV open sticking
4. SCV intermittent fault
5. Fuel system failure
• Air intrusion
• Insufficient gas

86E-7 – 98E-7 Series 15-181

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the SCV (MPROP) and the rail pressure sensor for deformation and cracks,
the condition of the connection, and whether the retainer is loose or removed.
• Check whether the SCV (MPROP) and the rail pressure sensor wiring is disconnected or
shorted to the power/ground line, or the wiring coating is peeled.

3. Failure diagnosis • Check the fuel system, common rail system, and supply pump. Exchange the PLV.
• If needed, exchange the parts of the fuel system or common rail system, supply pump.

 For details on the check method and procedure, refer to "Structure and Function, Testing and
Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-182 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1667: PLV (Time of PLV Valve Opening Error)

Failure Failure phenomenon
#B1667 PLV (Time of PLV Valve Opening Error)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Rail pressure sensor is normal. Fuel system
2. The cumulative opening time of the pressure control valve of common rail Supply pump
exceeds 5 hours. Rail pressure sensor
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Rail pressure sensor system failure
2. SCV drive circuit system failure
3. SCV open sticking
4. SCV intermittent fault
5. Fuel system failure
• Air intrusion
• Insufficient gas

86E-7 – 98E-7 Series 15-183

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the SCV (MPROP) and the rail pressure sensor for deformation and cracks,
the condition of the connection, and whether the retainer is loose or removed.
• Check whether the SCV (MPROP) and the rail pressure sensor wiring is disconnected or
shorted to the power/ground line, or the wiring coating is peeled.

3. Failure diagnosis • Check the fuel system, common rail system, and supply pump. Exchange the PLV.
• If needed, exchange the parts of the fuel system or common rail system, supply pump.

 For details on the check method and procedure, refer to "Structure and Function, Testing and
Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-184 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1668: PLV (Non-Performance)

Failure Failure phenomenon
#B1668 PLV (Non-Performance)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Rail pressure sensor is normal. Fuel system
2. The pressure control valve of common rail fails to open when abnormally high Supply pump
pressure of common rail occurred (rail pressure of 160 MPa or higher contin- Rail pressure sensor
ues for 10 seconds or longer).

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Rail pressure sensor system failure
2. SCV drive circuit system failure
3. SCV open sticking
4. SCV intermittent fault
5. Fuel system failure
• Air intrusion
• Insufficient gas

86E-7 – 98E-7 Series 15-185

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the SCV (MPROP) and the rail pressure sensor for deformation and cracks,
the condition of the connection, and whether the retainer is loose or removed.
• Check whether the SCV (MPROP) and the rail pressure sensor wiring is disconnected or
shorted to the power/ground line, or the wiring coating is peeled.

3. Failure diagnosis • Check the fuel system, common rail system, and supply pump.
• If needed, exchange the parts of the fuel system or common rail system, supply pump.

 For details on the check method and procedure, refer to "Structure and Function, Testing and
Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-186 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1665: PLV (Malfunction)

Failure Failure phenomenon
#B1665 PLV (Malfunction)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Rail pressure sensor is normal. Fuel system
2. Rail pressure deviates from the range from 50 to 120 MPa after common rail Supply pump
pressure control valve is opened. Rail pressure sensor

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Rail pressure sensor system failure
2. SCV drive circuit system failure
3. SCV open sticking
4. SCV intermittent fault
5. Fuel system failure
• Air intrusion
• Insufficient gas

86E-7 – 98E-7 Series 15-187

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the SCV (MPROP) and the rail pressure sensor for deformation and cracks,
the condition of the connection, and whether the retainer is loose or removed.
• Check whether the SCV (MPROP) and the rail pressure sensor wiring is disconnected or
shorted to the power/ground line, or the wiring coating is peeled.

3. Failure diagnosis • Check the fuel system, common rail system, and supply pump.
• If needed, exchange the parts of the fuel system or common rail system, supply pump.

 For details on the check method and procedure, refer to "Structure and Function, Testing and
Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-188 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ Rail pressure control

#B1669: Rail Press Control (Fuel Temp High in PLV V Open)

Failure Failure phenomenon
#B1669 Rail Press Control (Fuel Temp High in PLV V Open)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Rail pressure sensor is normal. Fuel system
2. The fuel temperature exceeds 80 °C after common rail pressure control valve Supply pump
is opened. Rail pressure sensor

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• The KDPF regeneration terminates.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Rail pressure sensor system failure
2. SCV drive circuit system failure
3. SCV open sticking
4. SCV intermittent fault
5. Fuel system failure
• Air intrusion
• Insufficient gas

86E-7 – 98E-7 Series 15-189

FAILURE CODE (DTC) GENERAL DESCRIPTION CRS (common rail system) related

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the SCV (MPROP) and the rail pressure sensor for deformation and cracks,
the condition of the connection, and whether the retainer is loose or removed.
• Check whether the SCV (MPROP) and the rail pressure sensor wiring is disconnected or
shorted to the power/ground line, or the wiring coating is peeled.

3. Failure diagnosis • Check the fuel system, common rail system, and supply pump.
• If needed, exchange the parts of the fuel system or common rail system, supply pump.

 For details on the check method and procedure, refer to "Structure and Function, Testing and
Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-190 86E-7 – 98E-7 Series

CRS (common rail system) related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1670: Rail Press Control (Pump or Fuel Temp Error)

Failure Failure phenomenon
#B1670 Rail Press Control (Pump or Fuel Temp Error)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Rail pressure sensor is normal. Connector
2. Either of the following is true. Wire harness
• The rail pressure sensor and the high-pressure pump drive circuit (MPROP) SCV (MPROP)
are abnormal. Fuel temperature sensor
• The rail pressure sensor and the fuel temperature sensor are abnormal. E-ECU

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Rail pressure sensor failure or that wiring failure
2. SCV failure or that wiring failure
3. Fuel temperature sensor failure or that wiring failure

 Diagnosis
• Refer to “Rail pressure sensor fault (high voltage) or (low voltage)”
• Refer to “SCV(MPROP) fault”
• Refer to “Fuel temperature sensor fault (high voltage) or (low voltage)”

86E-7 – 98E-7 Series 15-191

FAILURE CODE (DTC) GENERAL DESCRIPTION Actuator

Actuator

■ Intake throttle drive circuit

#B0660: No-load of Throttle Valve Drive H Bridge Circuit

Failure Failure phenomenon
#B0660 No-load of Throttle Valve Drive H Bridge Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. No-load (open circuit) of drive circuit is detected. Wire harness
Intake throttle
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The air intake throttle is fully opened.
• The KDPF regeneration terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• High side open circuit of the intake throttle drive circuit
• Low side open circuit of the intake throttle drive circuit
3. Intake throttle fault due to open circuit
4. E-ECU internal circuit fault

15-192 86E-7 – 98E-7 Series

Actuator FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1658: Power Short of Throttle Valve Drive H Bridge Out 1

Failure Failure phenomenon
#B1658 Power Short of Throttle Valve Drive H Bridge Out 1
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. Output terminal 1 of drive circuit is VB short circuit. Wire harness
Intake throttle
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The air Intake throttle is fully opened.
• The KDPF regeneration terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• High side power short circuit of the intake throttle drive circuit
3. Intake throttle fault due to open circuit
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-193

FAILURE CODE (DTC) GENERAL DESCRIPTION Actuator

#B1659: GND Short of Throttle Valve Drive H Bridge Out 1

Failure Failure phenomenon
#B1659 GND Short of Throttle Valve Drive H Bridge Out 1
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. Output terminal 1 of drive circuit is GND short circuit. Wire harness
Intake throttle
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The air intake throttle is fully opened.
• The KDPF regeneration terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• High side GND short circuit of the intake throttle drive circuit
3. Intake throttle fault due to GND short circuit
4. E-ECU internal circuit fault

15-194 86E-7 – 98E-7 Series

Actuator FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1660: O-load on the Drive H Bridge Cir of Throttle Valve

Failure Failure phenomenon
#B1660 O-load on the Drive H Bridge Cir of Throttle Valve
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The component temperature of the drive circuit exceeds the threshold value. Wire harness
Intake throttle
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The air intake throttle is fully opened.
• The KDPF regeneration terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Insulation failure of the connector
2. Wiring failure of the wire harness
• High side short circuit of the intake throttle drive circuit
• Low side short circuit of the intake throttle drive circuit
3. Intake throttle fault due to short circuit
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-195

FAILURE CODE (DTC) GENERAL DESCRIPTION Actuator

#B1661: VB P Short of Throttle Valve Drive H Bridge Out 2

Failure Failure phenomenon
#B1661 VB P Short of Throttle Valve Drive H Bridge Out 2
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. Output terminal 2 of drive circuit is VB short circuit. Wire harness
Intake throttle
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The air intake throttle is fully opened.
• The KDPF regeneration terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Low side power short circuit of the intake throttle drive circuit
3. Intake throttle fault due to power short circuit
4. E-ECU internal circuit fault

15-196 86E-7 – 98E-7 Series

Actuator FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1662: GND Short of Throttle Valve Drive H Bridge Out 2

Failure Failure phenomenon
#B1662 GND Short of Throttle Valve Drive H Bridge Out 2
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. Output terminal 2 of drive circuit is GND short circuit. Wire harness
Intake throttle
E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• The air intake throttle is fully opened.
• The KDPF regeneration terminates.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Low side GND short circuit of the intake throttle drive circuit
3. Intake throttle fault due to GND short circuit
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-197

FAILURE CODE (DTC) GENERAL DESCRIPTION Actuator

■ EGR

#B0404: EGR Voltage High Error

Failure Failure phenomenon
#B0404 EGR Voltage High Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Supply voltage to EGR is detected for more than 18 V for 5 seconds. Battery
2. Supply voltage to EGR valve is more than 18 V for more than 5 seconds. EGR valve

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Overcharge of the battery
2. Internal circuit failure of the EGR valve

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Failure diagnosis • Check the conduction of the wire harness.

• Check the battery voltage.

15-198 86E-7 – 98E-7 Series

Actuator FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1404: EGR Voltage Low Error

Failure Failure phenomenon
#B1404 EGR Voltage Low Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Supply voltage to EGR is detected for less than 8 V for 13 seconds. Wire harness
2. Supply voltage to EGR valve is less than 8 V for more than 13 seconds. Battery
EGR valve

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Deterioration of the battery
2. Power wire short-circuit of the EGR valve
3. Internal circuit failure of the EGR valve

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Failure diagnosis • Check the conduction of the wire harness.

• Check the battery voltage.

86E-7 – 98E-7 Series 15-199

FAILURE CODE (DTC) GENERAL DESCRIPTION Actuator

#B1409: EGR Feedback Error

Failure Failure phenomenon
#B1409 EGR Feedback Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Drive duty at 95 % is continued for 3 sec. EGR valve
2. Motor drive duty at the excessive condition is continued for a give period of
time.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Internal circuit failure of the EGR valve

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the EGR valve.

 For details on the exchange method and procedure, refer to "Structure and Function, Testing
and Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-200 86E-7 – 98E-7 Series

Actuator FAILURE CODE (DTC) GENERAL DESCRIPTION

#BG401: EGR ECM Data Error

Failure Failure phenomenon
#BG401 EGR ECM Data Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Transmission signal from ECU to EGR is lost for more than 1 second. EGR valve
2. Instruction packet cut-off from ECU is detected.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Internal circuit failure of the EGR valve

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the EGR valve for deformation and cracks, the condition of the connection,
and whether the retainer is loose or removed.
• Check whether the EGR valve or EGR valve relay wiring is disconnected or the wiring coating
is peeled.

3. Failure diagnosis • Check the fault indication again.

• If this DTC is detected again, exchange the harness or EGR valve.

86E-7 – 98E-7 Series 15-201

FAILURE CODE (DTC) GENERAL DESCRIPTION Actuator

#B0403: Open Circuit Between the EGR Motor Coils

Failure Failure phenomenon
#B0403 Open Circuit Between the EGR Motor Coils
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Open circuit is detected in one of the phases of UVW. EGR valve
2. Open circuit condition with the motor is detected.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. DC motor failure of the EGR valve

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the EGR valve.

 For details on the exchange method and procedure, refer to "Structure and Function, Testing
and Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-202 86E-7 – 98E-7 Series

Actuator FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1405: Short Circuit Between the EGR Motor Coils

Failure Failure phenomenon
#B1405 Short Circuit Between the EGR Motor Coils
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Overcurrent 18 A is detected. The energization is stopped after the detection EGR valve
and the energization starts again after 1 sec. Malfunction is notified after it is
detected for 3 times.
2. Overcurrent between the motor coils caused by short circuit is detected.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. DC motor failure of the EGR valve

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the EGR valve.

 For details on the exchange method and procedure, refer to "Structure and Function, Testing
and Adjusting, Disassembly and Assembly, and Maintenance Standard".

86E-7 – 98E-7 Series 15-203

FAILURE CODE (DTC) GENERAL DESCRIPTION Actuator

#B0488: EGR Position Sensor Error

Failure Failure phenomenon
#B0488 EGR Position Sensor Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Signal output is excessive or dropped. EGR valve
2. Excessive or dropped position sensor signal voltage is detected.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Internal circuit failure of the EGR valve

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the EGR valve.

 For details on the exchange method and procedure, refer to "Structure and Function, Testing
and Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-204 86E-7 – 98E-7 Series

Actuator FAILURE CODE (DTC) GENERAL DESCRIPTION

#B148A: EGR Stuck Open Valve Error

Failure Failure phenomenon
#B148A EGR Stuck Open Valve Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. There are 45 steps or more in the stopper all closed position and the open EGR valve
valve starting point at the time of initialization.
2. The number of steps between front opening and all closed at the time of initial-
ization is fault.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Sticking of the EGR valve

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the EGR valve.

 For details on the exchange method and procedure, refer to "Structure and Function, Testing
and Adjusting, Disassembly and Assembly, and Maintenance Standard".

86E-7 – 98E-7 Series 15-205

FAILURE CODE (DTC) GENERAL DESCRIPTION Actuator

#B049D: EGR Initialization Error

Failure Failure phenomenon
#B049D EGR Initialization Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Output signal of position sensor does not change in 64 ms or 128 ms or contin- EGR valve
uously changes in 1.6 sec or more.
2. The completion time of initialization exceeds the specified range.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Internal circuit failure of the EGR valve
2. Malfunction of the EGR valve
3. Sticking of the EGR valve

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the EGR valve.

 For details on the exchange method and procedure, refer to "Structure and Function, Testing
and Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-206 86E-7 – 98E-7 Series

Actuator FAILURE CODE (DTC) GENERAL DESCRIPTION

#BH401: EGR Target Value Out of Range

Failure Failure phenomenon
#BH401 EGR Target Value Out of Range
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The target position information from ECU is out of range for 10 - 40 hours. EGR valve
2. The direction opening from ECU is out of range for a given period of time. E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. E-ECU software fault

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the EGR valve.

86E-7 – 98E-7 Series 15-207

FAILURE CODE (DTC) GENERAL DESCRIPTION Actuator

#B1410: EGR High Temperature Thermistor Error

Failure Failure phenomenon
#B1410 EGR High Temperature Thermistor Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Thermistor output at 0.2 V or below is continued for 3 sec or more. EGR valve
2. The high temperature side thermistor inside the control unit is below 0.2 V.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Internal circuit failure of the EGR valve

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the EGR valve.

 For details on the exchange method and procedure, refer to "Structure and Function, Testing
and Adjusting, Disassembly and Assembly, and Maintenance Standard".

15-208 86E-7 – 98E-7 Series

Actuator FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1411: EGR Low Temperature Thermistor Error

Failure Failure phenomenon
#B1411 EGR Low Temperature Thermistor Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. Thermistor output at 0.2 V or below is continued for 3 sec or more. EGR valve
2. The low temperature side thermistor inside the control unit is below 0.2 V.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Internal circuit failure of the EGR valve

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the EGR valve.

 For details on the exchange method and procedure, refer to "Structure and Function, Testing
and Adjusting, Disassembly and Assembly, and Maintenance Standard".

86E-7 – 98E-7 Series 15-209

FAILURE CODE (DTC) GENERAL DESCRIPTION Actuator

■ Exhaust throttle

#B1438: Exhaust throttle (Voltage fault)

Failure Failure phenomenon
#B1438 Exhaust throttle (Voltage fault)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite.
2. When the power supply voltage becomes either of the following:
• The situation that the detected voltage is less than or equal to 6 V continues
for 10 seconds.
• The situation that the detected voltage is greater than or equal to 16 V contin-
ues for 1 second.

 Actions when a malfunction occurs

Fault mode
Limited operation
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the battery
2. Internal circuit failure of the EGR valve

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Failure diagnosis • Check the conduction of the wire harness.

• Check the battery voltage.

15-210 86E-7 – 98E-7 Series

Actuator FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1439: Exhaust throttle (Motor fault)

Failure Failure phenomenon
#B1439 Exhaust throttle (Motor fault)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite.
2. When any of the following is true:
• For every calculation cycle (5 ms) of control, the situation that IPD DIAG out-
put is equal to Low Edge input is detected for more than 4 times or 2 times
consecutively.
• In a 4 ms cycle, the situation of high-level output of IPD is detected for 10
times consecutively.
• Full-close learning voltage is greater than or equal to 0.295 V, and less than
or equal to 0.803 V.
• Full-open learning voltage is greater than or equal to 4.070 V, and less than
or equal to 4.578 V.
• The situation that motor drive duty is greater than ±90 % continues for 10
seconds.

 Actions when a malfunction occurs

Fault mode
Limited operation
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the DC motor of the exhaust throttle
2. Internal circuit failure of the exhaust throttle
3. Exhaust throttle sticking

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the exhaust throttle.

86E-7 – 98E-7 Series 15-211

FAILURE CODE (DTC) GENERAL DESCRIPTION Actuator

#B1440: Exhaust throttle (Sensor system fault)

Failure Failure phenomenon
#B1440 Exhaust throttle (Sensor system fault)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite.
2. When any of the following is true:
• The situation that the TPS supply voltage is less than or equal to 4.496 V
continues for 100 ms.
• The situation that the TPS supply voltage is greater than or equal to 5.501 V
continues for 100 ms.
• The situation that TPS supply voltage is less than or equal to 0.295 V contin-
ues for 100 ms.
• The situation that TPS supply voltage is greater than or equal to 4.578 V con-
tinues for 100 ms.
• The situation that the current position is less than or equal to (target value -
20AD) or the current position is greater than or equal to (target value - 20AD)
continues for 10 seconds.

 Actions when a malfunction occurs

Fault mode
Limited operation
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Internal circuit failure of the exhaust throttle
2. Exhaust throttle sticking

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the exhaust throttle.

15-212 86E-7 – 98E-7 Series

Actuator FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1441: Exhaust throttle (MPU fault)

Failure Failure phenomenon
#B1441 Exhaust throttle (MPU fault)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite.
2. When any of the following is true:
• ALU is abnormal.
• Mismatch in the checksum value of the ROM area used.
• The values written in and read by RAM don't match.
• Register is abnormal.
• ADC is abnormal.
• Status is abnormal.
• WDT is abnormal.

 Actions when a malfunction occurs

Fault mode
Limited operation
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Internal circuit failure of the exhaust throttle

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the exhaust throttle.

86E-7 – 98E-7 Series 15-213

FAILURE CODE (DTC) GENERAL DESCRIPTION Actuator

#B1442: Exhaust throttle (PCB fault)

Failure Failure phenomenon
#B1442 Exhaust throttle (PCB fault)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite.
2. When any of the following is true:
• The ambient temperature thermistor is greater than or equal to 160 °C and it
continues for 100 ms.
• The ambient temperature thermistor is less than or equal to 50 °C and it con-
tinues for 100 ms.

 Actions when a malfunction occurs

Fault mode
Limited operation
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Internal circuit failure of the exhaust throttle

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the exhaust throttle.

15-214 86E-7 – 98E-7 Series

Actuator FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1443: Exhaust throttle (CAN fault)

Failure Failure phenomenon
#B1443 Exhaust throttle (CAN fault)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite.
2. When any of the following is true:
• An initialization error of a CAN controller is detected.
• Any of the following is detected for 125 times.
• A CAN BusOff error is detected.
• A CAN CheckSum Diag error is detected.
• A CAN Reliability error is detected.
• A CAN Err Passive error is detected.
• A CAN reception time-out is detected.
• A CAN ACK error is detected.

 Actions when a malfunction occurs

Fault mode
Limited operation
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
3. Internal circuit failure of the exhaust throttle
4. ECU software fault

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the exhaust throttle for deformation and cracks, the condition of the connec-
tion, and whether the retainer is loose or removed.
• Check whether the exhaust throttle or EGR valve relay wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the fault indication again.

• If this DTC is detected again, exchange the harness or exhaust throttle.

86E-7 – 98E-7 Series 15-215

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

Communication related

■ CAN1

#BG10B: CAN1 (for EGR): Reception Time Out

Failure Failure phenomenon
#BG10B CAN1 (for EGR): Reception Time Out
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: E-ECU
• Key switch is ON. Connector
• Not in cranking status. Wire harness
• Battery voltage is 10 V or higher. EGR valve
2. A reception time out is detected at a fixed time.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Open-circuit or short-circuit of the wire harness
3. E-ECU internal circuit fault
4. EGR valve internal circuit fault

15-216 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

#BH107: Exhaust throttle (CAN message from the exhaust throttle time out)
Failure Failure phenomenon Exhaust throttle (CAN message from the exhaust throttle
#BH107
code (DTC) (Display of screen) time out)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. 2 seconds after the key switch was turned ON. E-ECU
2. No. Connector
Wire harness
Exhaust throttle

 Actions when a malfunction occurs

Fault mode
Limited operation
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Open-circuit or short-circuit of the wire harness
3. E-ECU internal circuit fault
4. Exhaust throttle internal circuit fault

86E-7 – 98E-7 Series 15-217

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

■ CAN2

#BG292: TSC1 (CAN Message) Reception Time Out (SA1)

Failure Failure phenomenon
#BG292 TSC1 (CAN Message) Reception Time Out (SA1)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: Connector
• Key switch is ON. Wire harness
• Not in cranking status. Machine controller
• Battery voltage is 10 V or higher. E-ECU
2. A reception time out is detected at a fixed time.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The following operations are selectable by application settings.
• ECU power OFF.
• TSC1 message reception recoveries.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. CAN communication error of the machine controller
2. Poor connection of the connector
3. Open-circuit or short-circuit of the wire harness
4. E-ECU internal circuit fault

15-218 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

86E-7 – 98E-7 Series 15-219

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

#BH301: TSC1 (CAN Message) Reception Time Out (SA2)

Failure Failure phenomenon
#BH301 TSC1 (CAN Message) Reception Time Out (SA2)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: Connector
• Key switch is ON. Wire harness
• Not in cranking status. Machine controller
• Battery voltage is 10 V or higher. E-ECU
2. A reception time out is detected at a fixed time.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. CAN communication error of the machine controller
2. Poor connection of the connector
3. Open-circuit or short-circuit of the wire harness
4. E-ECU internal circuit fault

15-220 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

86E-7 – 98E-7 Series 15-221

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

#BH292: Y_ECR1 (CAN Message) Reception Time Out

Failure Failure phenomenon
#BH292 Y_ECR1 (CAN Message) Reception Time Out
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: Connector
• Key switch is ON. Wire harness
• Not in cranking status. Machine controller
• Battery voltage is 10 V or higher. E-ECU
2. A reception time out is detected at a fixed time.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The following operations are selectable by application settings.
• ECU power OFF.
• Y_ECR1 message reception recoveries.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. CAN communication error of the machine controller
2. Poor connection of the connector
3. Open-circuit or short-circuit of the wire harness
4. E-ECU internal circuit fault

15-222 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

86E-7 – 98E-7 Series 15-223

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

#BH293: Y_EC (CAN Message) Reception Time Out

Failure Failure phenomenon
#BH293 Y_EC (CAN Message) Reception Time Out
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: Connector
• Key switch is ON. Wire harness
• Not in cranking status. Machine controller
• Battery voltage is 10 V or higher. E-ECU
2. A reception time out is detected at a fixed time.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The following operations are selectable by application settings.
• ECU power OFF.
• Y_EC message reception recoveries.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. CAN communication error of the machine controller
2. Poor connection of the connector
3. Open-circuit or short-circuit of the wire harness
4. E-ECU internal circuit fault

15-224 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

86E-7 – 98E-7 Series 15-225

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

#BH294: —
Failure Failure phenomenon
#BH294 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: Connector
• Key switch is ON. Wire harness
• Not in cranking status. Machine controller
• Battery voltage is 10 V or higher. E-ECU
2. A reception time out is detected at a fixed time.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The following operations are selectable by application settings.
• ECU power OFF.
• Y_RSS message reception recoveries.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. CAN communication error of the machine controller
2. Poor connection of the connector
3. Open-circuit or short-circuit of the wire harness
4. E-ECU internal circuit fault

15-226 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

86E-7 – 98E-7 Series 15-227

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

#BH296: —
Failure Failure phenomenon
#BH296 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: Connector
• Key switch is ON. Wire harness
• Not in cranking status. Machine controller
• Battery voltage is 10 V or higher. E-ECU
2. A reception time out is detected at a fixed time.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The following operations are selectable by application settings.
• ECU power OFF.
• VH message reception recoveries.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. CAN communication error of the machine controller
2. Poor connection of the connector
3. Open-circuit or short-circuit of the wire harness
4. E-ECU internal circuit fault

15-228 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

86E-7 – 98E-7 Series 15-229

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

#BH298: —
Failure Failure phenomenon
#BH298 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: Connector
• Key switch is ON. Wire harness
• Not in cranking status. Machine controller
• Battery voltage is 10 V or higher. E-ECU
2. A reception time out is detected at a fixed time.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The following operations are selectable by application settings.
• ECU power OFF.
• Y_ECM3 message reception recoveries.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. CAN communication error of the machine controller
2. Poor connection of the connector
3. Open-circuit or short-circuit of the wire harness
4. E-ECU internal circuit fault

15-230 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

86E-7 – 98E-7 Series 15-231

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

#BG168: —
Failure Failure phenomenon
#BG168 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: Connector
• Key switch is ON. Wire harness
• Not in cranking status. Machine controller
• Battery voltage is 10 V or higher. E-ECU
2. There is no response to the VIN request for 3 times.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. CAN communication error of the machine controller
2. Poor connection of the connector
3. Open-circuit or short-circuit of the wire harness
4. E-ECU internal circuit fault

15-232 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

86E-7 – 98E-7 Series 15-233

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

#BK002: —
Failure Failure phenomenon
#BK002 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: Connector
• Key switch is ON. Wire harness
• Not in cranking status. Machine controller
• Battery voltage is 10 V or higher. E-ECU
2. The received VI does not match the existed VI in ECU.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. CAN communication error of the machine controller
2. E-ECU internal circuit fault

15-234 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

86E-7 – 98E-7 Series 15-235

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

#BH300: —
Failure Failure phenomenon
#BH300 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: Connector
• Key switch is ON. Wire harness
• Not in cranking status. Machine controller
• Battery voltage is 10 V or higher. E-ECU
2. A reception time out is detected at a fixed time.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The following operations are selectable by application settings.
• ECU power OFF.
• Y_ETCP1 message reception recoveries.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. CAN communication error of the machine controller
2. Poor connection of the connector
3. Open-circuit or short-circuit of the wire harness
4. E-ECU internal circuit fault

15-236 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

86E-7 – 98E-7 Series 15-237

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

#BH302: —
Failure Failure phenomenon
#BH302 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: Connector
• 2 seconds passes after the key switch was turned ON. Wire harness
• Not in cranking status. Machine controller
• ECU power is not OFF. E-ECU
• Voltage value is 10 V or higher.
2. A fixed time passes after a reception time out was detected for certain times.
Count resets after normal communication.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: • ECU power OFF.
• EBC1 message reception recoveries.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. CAN communication error of the machine controller
2. Poor connection of the connector
3. Open-circuit or short-circuit of the wire harness
4. E-ECU internal circuit fault

15-238 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

86E-7 – 98E-7 Series 15-239

FAILURE CODE (DTC) GENERAL DESCRIPTION Communication related

#BH303: Y_DPFIF (CAN Message) Reception Time Out

Failure Failure phenomenon
#BH303 Y_DPFIF (CAN Message) Reception Time Out
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The following conditions are all true: Connector
• Key switch is ON. Wire harness
• Not in cranking status. Machine controller
• Battery voltage is 10 V or higher. E-ECU
2. A reception time out is detected at a fixed time.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The following operations are selectable by application settings.
• ECU power OFF.
• Y_DPFIF message reception recoveries.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. CAN communication error of the machine controller
2. Poor connection of the connector
3. Open-circuit or short-circuit of the wire harness
4. E-ECU internal circuit fault

15-240 86E-7 – 98E-7 Series

Communication related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-104.

86E-7 – 98E-7 Series 15-241

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

ECU related

■ EEPROM

#B0601: EEPROM Memory Deletion Error

Failure Failure phenomenon
#B0601 EEPROM Memory Deletion Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. When page (sector) switches. E-ECU
2. EEPROM deletion malfunctions.
The EEPROM has two pages and uses them alternately. When the first page
becomes full, the second page will be cleared for writing into. Similarly, when
the second page becomes full, the first page will be cleared for writing into.
This error occurs when the page fails to be cleared during page switching.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.

 For details on the diagnosis method and procedure, see Chapter 16 P16-107.

15-242 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B160E: EEPROM Memory Read Error

Failure Failure phenomenon
#B160E EEPROM Memory Read Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. When read-accessing. E-ECU
2. EEPROM reading malfunctions.
This error is determined based on the check sum, and this is performed on all
EEPROM.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.

 For details on the diagnosis method and procedure, see Chapter 16 P16-107.

86E-7 – 98E-7 Series 15-243

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B160F: EEPROM Memory Writing Error

Failure Failure phenomenon
#B160F EEPROM Memory Writing Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. When write-accessing. E-ECU
2. EEPROM writing malfunctions.
This error occurs when there are 3 failed attempts to write one data.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The EGR is fully closed.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.

 For details on the diagnosis method and procedure, see Chapter 16 P16-107.

15-244 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

■ ECU internal fault

#B1613: CY146 SPI Communication Error

Failure Failure phenomenon
#B1613 CY146 SPI Communication Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. E-ECU
2. A communication fault between the CPU and the H bridge control IC.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-245

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B1608: Excessive Voltage of Supply 1

Failure Failure phenomenon
#B1608 Excessive Voltage of Supply 1
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. E-ECU
2. The 5 V supply voltage to the actuator drive is excessive.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

15-246 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1617: Insufficient Voltage of Supply 1

Failure Failure phenomenon
#B1617 Insufficient Voltage of Supply 1
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. E-ECU
2. The 5 V supply voltage to the actuator drive is insufficient.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-247

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B1609: Sensor Supply Voltage Error 1

Failure Failure phenomenon
#B1609 Sensor Supply Voltage Error 1
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The 5 V supply voltage of sensor exceeds the threshold value. Wire harness
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector of the sensor that uses sensor power supply 1(K43 or K44 terminal)
2. Wiring failure of the wire harness
3. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of sensor that uses sensor power supply 1 (K43 or K44 terminal) for deformation
and cracks, the condition of the connection, and whether the retainer is loose or removed.
• Check whether the sensor that uses sensor power supply 1 wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the fault indication again.

• If this DTC is detected again, exchange the harness or E-ECU.

15-248 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1618: Sensor Supply Voltage Error 2

Failure Failure phenomenon
#B1618 Sensor Supply Voltage Error 2
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The 5 V supply voltage of sensor exceeds the threshold value. Wire harness
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector of the sensor that uses sensor power supply 2 (K45 or A08 terminal)
2. Wiring failure of the wire harness
3. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of sensor that uses sensor power supply 2 (K45 or A08 terminal) for deformation
and cracks, the condition of the connection, and whether the retainer is loose or removed.
• Check whether the sensor that uses sensor power supply 2 wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the fault indication again.

• If this DTC is detected again, exchange the harness or E-ECU.

86E-7 – 98E-7 Series 15-249

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B1619: Sensor Supply Voltage Error 3

Failure Failure phenomenon
#B1619 Sensor Supply Voltage Error 3
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The 5 V supply voltage of sensor exceeds the threshold value. Wire harness
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector of the sensor that uses sensor power supply 3 (A07 terminal)
2. Wiring failure of the wire harness
3. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of sensor that uses sensor power supply 3 (A07 terminal) for deformation and
cracks, the condition of the connection, and whether the retainer is loose or removed.
• Check whether the sensor that uses sensor power supply 3 wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the fault indication again.

• If this DTC is detected again, exchange the harness or E-ECU.

15-250 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1626: Actuator Drive Circuit 1 Short to Ground

Failure Failure phenomenon
#B1626 Actuator Drive Circuit 1 Short to Ground
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The overcurrent in UB2 terminal is detected by IC in the ECU. Wire harness
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector of the actuator that uses 12 V power supply 1 (UB2: K68 terminal)
2. Wiring failure of the wire harness
• GND short circuit of the 12 V power supply 1 (UB2: K68 terminal) wire
3. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the actuator that uses 12 V power supply 1 (UB2: K68 terminal) for deforma-
tion and cracks, the condition of the connection, and whether the retainer is loose or removed.
• Check whether the actuator that uses 12 V power supply 1 wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the fault indication again.

• If this DTC is detected again, exchange the harness or E-ECU.

86E-7 – 98E-7 Series 15-251

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B1633: Actuator Drive Circuit 2 Short to Ground

Failure Failure phenomenon
#B1633 Actuator Drive Circuit 2 Short to Ground
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The overcurrent in UB3 terminal is detected by IC in the ECU. Wire harness
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector of the actuator that uses 12 V power supply 2 (UB3: K90 or A50 terminal)
2. Wiring failure of the wire harness
• GND short circuit of the 12 V power supply 2 (UB3: K90 or A50 terminal) wire
3. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the actuator that uses 12 V power supply 2 (UB3: K90 or A50 terminal) for
deformation and cracks, the condition of the connection, and whether the retainer is loose or
removed.
• Check whether the actuator that uses 12 V power supply 2 wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the fault indication again.

• If this DTC is detected again, exchange the harness or E-ECU.

15-252 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1467: Actuator Drive Circuit 3 Short to Ground

Failure Failure phenomenon
#B1467 Actuator Drive Circuit 3 Short to Ground
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. The overcurrent in UB5 terminal is detected by IC in the ECU. Wire harness
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector of the actuator that uses 12 V power supply 3 (UB5: K73 terminal)
2. Wiring failure of the wire harness
• GND short circuit of the 12 V power supply 3 (UB5: K73 terminal) wire
3. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the actuator that uses 12 V power supply 3 (UB5: K73 terminal) for deforma-
tion and cracks, the condition of the connection, and whether the retainer is loose or removed.
• Check whether the actuator that uses 12 V power supply 3 wiring is disconnected or the wiring
coating is peeled.

3. Failure diagnosis • Check the fault indication again.

• If this DTC is detected again, exchange the harness or E-ECU.

86E-7 – 98E-7 Series 15-253

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B1469: AD Converter Error 1

Failure Failure phenomenon
#B1469 AD Converter Error 1
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. E-ECU
2. A pulse error is detected through diagnosis of the AD converter.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

15-254 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1470: AD Converter Error 2

Failure Failure phenomenon
#B1470 AD Converter Error 2
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. E-ECU
2. A voltage error is detected through diagnosis of the AD converter.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-255

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B1471: External Monitoring IC and CPU Error 1

Failure Failure phenomenon
#B1471 External Monitoring IC and CPU Error 1
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. E-ECU
2. An error is detected through mutual diagnosis of the external monitoring IC
and the CPU.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

15-256 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1472: External Monitoring IC and CPU Error 2

Failure Failure phenomenon
#B1472 External Monitoring IC and CPU Error 2
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. E-ECU
2. A communication error is detected between the external monitoring IC and the
CPU.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-257

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B1473: ROM Error

Failure Failure phenomenon
#B1473 ROM Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. ECU power self-maintains after the key switch was turned OFF. E-ECU
2. The checksum of the all ROM areas is abnormal.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

15-258 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1474: Shutoff Path Error 1

Failure Failure phenomenon
#B1474 Shutoff Path Error 1
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During shutoff path test (operation diagnosis of the isolation function of injector E-ECU
current) by the external monitoring IC, which is implemented after turning on
the ECU power.
2. A response error from CPU to the external monitoring IC is detected by the
external monitoring IC.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-259

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B1475: Shutoff Path Error 2

Failure Failure phenomenon
#B1475 Shutoff Path Error 2
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During shutoff path test (operation diagnosis of the isolation function of injector E-ECU
current) by the external monitoring IC, which is implemented after turning on
the ECU power.
2. An operation error of shutoff path test is detected by the external monitoring
IC.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

15-260 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1476: Shutoff Path Error 3

Failure Failure phenomenon
#B1476 Shutoff Path Error 3
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During shutoff path test (operation diagnosis of the isolation function of injector E-ECU
current) by the external monitoring IC, which is implemented after turning on
the ECU power.
2. A response time error of shutoff path test is detected by the external monitor-
ing IC.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-261

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B1477: Shutoff Path Error 4

Failure Failure phenomenon
#B1477 Shutoff Path Error 4
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During shutoff path test (operation diagnosis of the isolation function of injector E-ECU
current) by the external monitoring IC, which is implemented after turning on
the ECU power.
2. A communication error of shutoff path test is detected by the external monitor-
ing IC.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

15-262 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1478: Shutoff Path Error 5

Failure Failure phenomenon
#B1478 Shutoff Path Error 5
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During shutoff path test (operation diagnosis of the isolation function of injector E-ECU
current) by the external monitoring IC, which is implemented after turning on
the ECU power.
2. An insufficient value of voltage in shutoff path test is detected by the external
monitoring IC.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-263

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B1479: Shutoff Path Error 6

Failure Failure phenomenon
#B1479 Shutoff Path Error 6
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During shutoff path test (operation diagnosis of the isolation function of injector E-ECU
current) by the external monitoring IC, which is implemented after turning on
the ECU power.
2. An error of the external monitoring IC in shutoff path test is detected by the
external monitoring IC.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

15-264 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1480: Shutoff Path Error 7

Failure Failure phenomenon
#B1480 Shutoff Path Error 7
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During shutoff path test (operation diagnosis of the isolation function of injector E-ECU
current) by the external monitoring IC, which is implemented after turning on
the ECU power.
2. An error of OS call time in shutoff path test is detected by the external monitor-
ing IC.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-265

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B1481: Shutoff Path Error 8

Failure Failure phenomenon
#B1481 Shutoff Path Error 8
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During shutoff path test (operation diagnosis of the isolation function of injector E-ECU
current) by the external monitoring IC, which is implemented after turning on
the ECU power.
2. An error of positive test of shutoff path test is detected by the external monitor-
ing IC.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

15-266 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1482: Shutoff Path Error 9

Failure Failure phenomenon
#B1482 Shutoff Path Error 9
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During shutoff path test (operation diagnosis of the isolation function of injector E-ECU
current) by the external monitoring IC, which is implemented after turning on
the ECU power.
2. An error of operation time of shutoff path test is detected by the external moni-
toring IC.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-267

FAILURE CODE (DTC) GENERAL DESCRIPTION ECU related

#B1483: Shutoff Path Error 10

Failure Failure phenomenon
#B1483 Shutoff Path Error 10
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. During shutoff path test (operation diagnosis of the isolation function of injector E-ECU
current) by the external monitoring IC, which is implemented after turning on
the ECU power.
2. An excessive value of voltage in shutoff path test is detected by the external
monitoring IC.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

15-268 86E-7 – 98E-7 Series

ECU related FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1484: Recognition Error of Engine Speed

Failure Failure phenomenon
#B1484 Recognition Error of Engine Speed
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. E-ECU
2. An error is detected through mutual diagnosis of engine speed.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of the E-ECU internal circuit

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power on and off.
• If this DTC is detected again, exchange the E-ECU.

86E-7 – 98E-7 Series 15-269

FAILURE CODE (DTC) GENERAL DESCRIPTION Contact input related

Contact input related

■ Air cleaner switch

#B1101: —
Failure Failure phenomenon
#B1101 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The power switch is turned on and the battery voltage is 9 V or more. Air cleaner
2. The air cleaner switch is turned on continuously for 10 sec. Wire harness
Air cleaner switch
E-ECU

 Actions when a malfunction occurs

Settings of the actions during a air cleaner fault
No Yes
Fault mode [Continuous operation]: [Limited operation]:
The engine continues to operate without limitations The engine operation is limited.
after the malfunction is detected.
Limited operation No Yes: The high idle speed or the engine output maxi-
mum injection quantity is limited. (Actions differ
by the customer setting.)
Reset criteria Yes: The fault mode is released when the ECU Yes: The fault mode is released when the ECU
power off is detected. power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Clogged air cleaner
2. Wiring failure of the wire harness
• Power short circuit of the air cleaner switch wiring
3. Air cleaner switch malfunction
• Power short circuit of the air cleaner switch internal wiring
4. E-ECU internal circuit fault

15-270 86E-7 – 98E-7 Series

Contact input related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check whether the input signal of the air cleaner switch is correctly recognized.

 For details on the diagnosis method and procedure, see Chapter 16 P16-78.

2. Engine check • Turn off the ECU power and stop the engine.
• Check the air cleaner.
• After a few moments, turn on the power switch and check whether DTC is detected.

3. Failure diagnosis • Check the air cleaner switch system.

 For details on the diagnosis method and procedure, see Chapter 16 P16-78.

86E-7 – 98E-7 Series 15-271

FAILURE CODE (DTC) GENERAL DESCRIPTION Contact input related

■ Oil/water separator switch

#B1151: —
Failure Failure phenomenon
#B1151 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The power switch is turned on and the battery voltage is 9 V or more. Oil/water separator
2. The oil/water separator switch is turned on continuously for 10 sec. Connector
Wire harness
Oil/water separator switch
E-ECU

 Actions when a malfunction occurs

Settings of the actions during a oil/water separator fault
No Yes
Fault mode [Continuous operation]: [Limited operation]:
The engine continues to operate without limitations The engine operation is limited.
after the malfunction is detected.
Limited operation No Yes: The high idle speed or the engine output maxi-
mum injection quantity is limited. (Actions differ
by the customer setting.)
Reset criteria Yes: The fault mode is released when the ECU Yes: The fault mode is released when the ECU
power off is detected. power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Oil/water separator malfunction
2. Wiring failure of the wire harness
• Power short circuit of the oil/water separator switch wiring
3. Oil/water separator switch malfunction
• Power short circuit of the oil/water separator switch internal wiring
4. E-ECU internal circuit fault

15-272 86E-7 – 98E-7 Series

Contact input related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check whether the input signal of the water separator switch is correctly recognized.

 For details on the diagnosis method and procedure, see Chapter 16 P16-78.

2. Engine check • Turn off the ECU power and stop the engine.
• Check the oil/water separator.
• After a few moments, turn on the power switch and check whether DTC is detected.

3. Failure diagnosis • Check the oil/water separator switch system.

 For details on the diagnosis method and procedure, see Chapter 16 P16-78.

86E-7 – 98E-7 Series 15-273

FAILURE CODE (DTC) GENERAL DESCRIPTION Contact input related

■ Charge switch

#B1562: Charge Switch Open Circuit

Failure Failure phenomenon
#B1562 Charge Switch Open Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The power switch is turned on and the judgment completion criteria is incom- Connector
plete. Wire harness
2. The charge switch is turned off continuously for 1 sec and the judgment is Charge switch
formed. E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
The engine continues to operate without limitations after the malfunction is detected.
Limited operation No
Reset criteria Yes: The fault mode is automatically released when the charge switch is turned on.
Or released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of connector
2. Wiring failure of the wire harness
• Open circuit or power short circuit of the charge switch wiring
3. Charge switch malfunction
• Open circuit or power short circuit of the charge switch internal wiring
4. E-ECU internal circuit fault

15-274 86E-7 – 98E-7 Series

Contact input related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check whether the input signal of the charge switch is correctly recognized.

 For details on the diagnosis method and procedure, see Chapter 16 P16-74.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the charge switch for deformation and cracks, the condition of the connection,
and whether the retainer is loose or removed.
• Check whether the charge switch wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

• Check the operation of the charge switch.

 For details on the diagnosis method and procedure, see Chapter 16 P16-74.

86E-7 – 98E-7 Series 15-275

FAILURE CODE (DTC) GENERAL DESCRIPTION Contact input related

#B1568: Charge Alarm

Failure Failure phenomenon
#B1568 Charge Alarm
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite Alternator
2. The power switch is turned on and the charge switch is turned on and  (engine Connector
speed > 600 min-1) continues for 10 sec after the completion of the engine start. Wire harness
The CAL value allows switching between “after the completion of the engine Charge switch
E-ECU
start” and “engine speed > 600 min-1”.

 Actions when a malfunction occurs

Setting of the charge alarm operation
No Yes
Fault mode [Continuous operation]: [Limited operation]:
The engine continues to operate without limitations The engine operation is limited.
after the malfunction is detected.
Limited operation No Yes: The high idle speed or the maximum injection
quantity is limited. (Actions differ by the cus-
tomer setting.)
Reset criteria Yes: The fault mode is automatically released when Yes: The fault mode is automatically released when
the charge switch is turned off. the charge switch is turned off.
Or released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Battery charge malfunction
2. Alternator malfunction
3. Wiring failure of the wire harness
• GND short circuit of the charge switch wiring
4. Charge switch malfunction
• GND short circuit of the charge switch internal wiring
5. E-ECU internal circuit fault

15-276 86E-7 – 98E-7 Series

Contact input related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check whether the input signal of the charge switch is correctly recognized.

 For details on the diagnosis method and procedure, see Chapter 16 P16-74.

2. Engine check • Turn off the ECU power and stop the engine.
• Check the engine charging equipment.
• After checking, turn on the power switch and check for the DTC detection.

3. Failure diagnosis • Check the charge switch system.

 For details on the diagnosis method and procedure, see Chapter 16 P16-74.

86E-7 – 98E-7 Series 15-277

FAILURE CODE (DTC) GENERAL DESCRIPTION Contact input related

■ Oil pressure switch

#B1192: Oil Pressure Switch Open Circuit

Failure Failure phenomenon
#B1192 Oil Pressure Switch Open Circuit
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The power switch is turned on and the battery voltage  9 V and the judgment Connector
completion criteria is incomplete. Wire harness
2. Judged when the oil pressure SW-OFF condition continues for 1 sec. Oil pressure switch
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
The engine continues to operate without limitations after the malfunction is detected.
Limited operation No
Reset criteria Yes: The fault mode is automatically released when the oil pressure switch is turned on.
Or released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of connector
2. Wiring failure of the wire harness
• Open circuit or power short circuit of the oil pressure switch wiring
3. Oil pressure switch fault
• Open circuit or power short circuit of the oil pressure switch internal wiring
4. E-ECU internal circuit fault

15-278 86E-7 – 98E-7 Series

Contact input related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check whether the input signal is correctly recognized.

 For details on the diagnosis method and procedure, see Chapter 16 P16-74.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the oil pressure switch for deformation and cracks, the condition of the con-
nection, and whether the retainer is loose or removed.
• Check whether the oil pressure switch wiring is disconnected or the wiring coating is peeled.

3. Failure diagnosis • Check the conduction of the oil pressure switch.

• Check the conduction of the wire harness.
• Check the operation of the oil pressure switch.

 For details on the diagnosis method and procedure, see Chapter 16 P16-74.

86E-7 – 98E-7 Series 15-279

FAILURE CODE (DTC) GENERAL DESCRIPTION Contact input related

#B1198: Oil Pressure Low Error Alarm

Failure Failure phenomenon
#B1198 Oil Pressure Low Error Alarm
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. The key switch is turned on  and the engine speed > 600 min-1 after the com- Oil pressure equipment
pletion of the engine start and the battery voltage is 9 V or more. Wire harness
2. The oil pressure switch is turned on for a certain amount of time. Oil pressure switch
 The CAL value allows switching between “after the completion of the engine E-ECU
start” and “engine speed > 600 min-1”.

 Actions when a malfunction occurs

Settings of the actions during a low oil pressure alarm
No Yes
Fault mode [Continuous operation]: [Limited operation]:
The engine continues to operate without limitations The engine operation is limited.
after the malfunction is detected.
Limited operation No Yes: The high idle speed or the maximum injection
quantity is limited. (Actions differ by the cus-
tomer setting.)
Reset criteria Yes: The fault mode is released when the ECU Yes: The fault mode is released when the ECU
power is turned off. power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Oil pressure low
2. Oil pressure equipment malfunction
3. Wiring failure of the wire harness
• GND short circuit of the oil pressure switch wiring
4. Oil pressure switch fault
• GND short circuit of the oil pressure switch internal wiring
5. E-ECU internal circuit fault

15-280 86E-7 – 98E-7 Series

Contact input related FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check whether the input signal is correctly recognized.

 For details on the diagnosis method and procedure, see Chapter 16 P16-74.

2. Engine check • Turn off the ECU power and stop the engine.
• Check the lubrication system.
• After checking, turn on the power switch and check for the DTC detection.

3. Failure diagnosis • Check the oil pressure switch system.

 For details on the diagnosis method and procedure, see Chapter 16 P16-74.

86E-7 – 98E-7 Series 15-281

FAILURE CODE (DTC) GENERAL DESCRIPTION Post treatment control

Post treatment control

■ KDPF

#B2463: Overaccumulation (Method C)

Failure Failure phenomenon
#B2463 Overaccumulation (Method C)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. KDPF intermediate temperature sensor sys-
2. When the transition is made to the recovery regeneration mode due to the tem
overaccumulation judgment of PM accumulated quantity (method C).

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
The engine continues to operate without limitations after the malfunction is detected.
Limited operation No
Reset criteria Yes: The fault mode is automatically released when the recovery is made from the condition in which the
recovery regeneration is requested.
Remarks When this error occurred, the “recovery regeneration standby” error is detected at the same time.

 Presumed cause of the malfunction or the abnormal condition

1. Insufficient regeneration capability due to the low operation load
2. Regeneration for the stationary regeneration request is not performed
3.  KDPF intermediate temperature sensor system fault

 There are cases in which this error occurs due to the low estimation of the regeneration quantity due to “KDPF inter-
mediate temperature sensor abnormal low temperature”. When this occurs at the same time, be sure to perform the
failure diagnosis for “KDPF intermediate temperature sensor temperature abnormal low temperature” in advance.

15-282 86E-7 – 98E-7 Series

Post treatment control FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1463: Overaccumulation (Method P)

Failure Failure phenomenon
#B1463 Overaccumulation (Method P)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. KDPF differential pressure sensor system
2. When the transition is made to the recovery regeneration mode due to the
overaccumulation judgment of PM accumulated quantity (method P).

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
The engine continues to operate without limitations after the malfunction is detected.
Limited operation No
Reset criteria Yes: The fault mode is automatically released when the recovery is made from the condition in which the
recovery regeneration is requested.
Remarks When this error occurred, the “recovery regeneration standby” error is detected at the same time.

 Presumed cause of the malfunction or the abnormal condition

1. Insufficient regeneration capability due to the low operation load
2. Regeneration for the stationary regeneration request is not performed
3.  KDPF differential pressure sensor fault

 There are cases in which this error occurs due to the high estimation of the method P regeneration quantity due to
“KDPF differential pressure sensor differential pressure abnormal rise”. When this occurs at the same time, be sure to
perform the failure diagnosis for “KDPF differential pressure sensor differential pressure abnormal rise” in advance.

86E-7 – 98E-7 Series 15-283

FAILURE CODE (DTC) GENERAL DESCRIPTION Post treatment control

#B2458: Defective Regeneration (StationaryRegene. Failure)

Failure Failure phenomenon
#B2458 Defective Regeneration (StationaryRegene. Failure)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. KDPF intermediate temperature sensor system
2. When the transition is made to the recovery regeneration mode due to incom- Injector
plete stationary regeneration within the specified time. KDOC

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
The engine continues to operate without limitations after the malfunction is detected.
Limited operation No
Reset criteria Yes: The fault mode is automatically released when the recovery is made from the condition in which the
recovery regeneration is requested.
Remarks When this error occurred, the “recovery regeneration standby” error is detected at the same time.

 Presumed cause of the malfunction or the abnormal condition

1.  KDPF intermediate temperature sensor system fault
2. KDOC deterioration or KDOC breakage due to the external factor such as sulfur poisoning
3. Injector defect
• Decrease in injection quantity
• Injection timing malfunction

 There are cases in which this error occurs due to the regeneration defect judgment caused by “KDPF intermediate
temperature sensor temperature abnormal low temperature”. When this is detected at the same time, be sure to per-
form the failure diagnosis for “KDPF intermediate temperature sensor temperature abnormal low temperature” in
advance.

15-284 86E-7 – 98E-7 Series

Post treatment control FAILURE CODE (DTC) GENERAL DESCRIPTION

#B2459: Defective Regeneration (StationaryR Not Performed)

Failure Failure phenomenon
#B2459 Defective Regeneration (StationaryR Not Performed)
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. When the transition is made to the backup mode due to the stationary regener- Wire harness
ation not performed in the specified time during the stationary regeneration Regeneration request lamp
request. Regeneration request switch
E-ECU

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
The engine continues to operate without limitations after the malfunction is detected.
Limited operation No
Reset criteria Yes: The fault mode is automatically released when the recovery is made from the condition in which the
recovery regeneration is requested.
Remarks When this error occurred, the “recovery regeneration standby” error is detected at the same time.

 Presumed cause of the malfunction or the abnormal condition

1. Poor connection of the connector
2. Wiring failure of the wire harness
• Regeneration for the stationary regeneration request is not performed
• Oversight due to the regeneration request lamp malfunction
• Regeneration not performed due to the regeneration request switch malfunction
3. When the engine speed is dropped to low idling during regeneration and abandoned
4. E-ECU internal circuit fault

86E-7 – 98E-7 Series 15-285

FAILURE CODE (DTC) GENERAL DESCRIPTION Post treatment control

■ KDPF OP interface

#B242F: Ash Cleaning Request 1

Failure Failure phenomenon
#B242F Ash Cleaning Request 1
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. KDPF
2. The ash accumulation density is greater than or equal to 50 g/L, and less than E-ECU
60 g/L.

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: The maximum engine torque is limited to 85 %.
Reset criteria Yes: The fault mode is automatically released when the ash cleaning request is not detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. E-ECU internal circuit fault
2.  Increase in the actual differential pressure of the soot filter
• Ash is accumulated

 There are cases in which the differential pressure does not rise drastically and the actual ash accumulation is little.
When this error occurs, it is highly possible that the engine has not been used for a long time. In such a case, it is
required to perform the KDPF maintenance.

15-286 86E-7 – 98E-7 Series

Post treatment control FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1420: Ash Cleaning Request 2

Failure Failure phenomenon
#B1420 Ash Cleaning Request 2
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. KDPF
2. Ash accumulation density is 60 g/L or more. E-ECU

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is automatically released when the ash cleaning request is not detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. E-ECU internal circuit fault
2.  Increase in the actual differential pressure of the soot filter
• Ash is accumulated

 There are cases in which the differential pressure does not rise drastically and the actual ash accumulation is little.
When this error occurs, it is highly possible that the engine has not been used for a long time. In such a case, it is
required to perform the KDPF maintenance.

86E-7 – 98E-7 Series 15-287

FAILURE CODE (DTC) GENERAL DESCRIPTION Post treatment control

#B1421: Stationary Regeneration Standby

Failure Failure phenomenon
#B1421 Stationary Regeneration Standby
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Injector
2. The transition is made to the stationary regeneration mode for the factors E-ECU
except for the SW/CAN direction from the outside during the stationary regen- KDOC
eration. Piping

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• Engine derates further after 120 min.
• The maximum engine torque is limited to 50 %.
Reset criteria Yes: The fault mode is automatically released when the stationary regeneration standby is not detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Insufficient regeneration capability due to the low operation load
2. Because the conditions of reset regeneration and regeneration forbidden switch turned on are continued for a
given period of time
3. E-ECU internal circuit fault
4. KDOC deterioration due to the external factor such as sulfur poisoning
• Increase in activated temperature
5. Blow-by of combustion gas
• Catalytic damage
• Piping damage in the passage to KDOC
6. Injector defect
• Decrease in injection quantity
• Injection timing malfunction

15-288 86E-7 – 98E-7 Series

Post treatment control FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1424: Backup Mode

Failure Failure phenomenon
#B1424 Backup Mode
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Injector
2. The transition is made to the recovery regeneration mode and while the recov- E-ECU
ery regeneration is not performed. KDOC
Piping

 Actions when a malfunction occurs

Fault mode [Limited operation]:
The engine operation is limited.
Limited operation Yes: • Engine derates immediately during sensor fails.
• The maximum engine torque is limited to 85 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
• The EGR is fully closed.
• Engine derates further after 15 min.
• The maximum engine torque is limited to 50 %.
• The engine speed is limited to the [maximum torque speed +200 min-1].
Reset criteria Yes: The fault mode is automatically released when the recovery regeneration standby is not detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. It is abandoned for a given period of time in the stationary regeneration standby emergency mode
2. E-ECU internal circuit fault
3. KDOC deterioration due to the external factor such as sulfur poisoning
• Increase in activated temperature
4. Blow-by of combustion gas
• Catalytic damage
• Piping damage in the passage to KDOC
5. Injector defect
• Decrease in injection quantity
• Injection timing malfunction

Note: When this error is detected, the “overaccumulation (method C)”, “overaccumulation (method P)”, “regeneration
defect (stationary regeneration failure)”, “regeneration defect (stationary regeneration not performed)” are
detected at the same time. Be sure to perform the failure diagnosis for the respective part.

86E-7 – 98E-7 Series 15-289

FAILURE CODE (DTC) GENERAL DESCRIPTION Post treatment control

#B1425: —
Failure Failure phenomenon
#B1425 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Regeneration prohibition switch (including
2. The post injection is inhibited by prohibition SW of KDPF regeneration when CAN control)
the operation transmitted to the reset regeneration mode.

 Actions when a malfunction occurs

Fault mode [Continuous operation]:
Engine control is not obstructed.
Limited operation No
Reset criteria Yes: Error determination conditions are not met.
Remarks

 Presumed cause of the malfunction or the abnormal condition

The mode is reset regeneration, but the regeneration is prohibited by the regeneration prohibition switch (including
CAN control) and the regeneration cannot be performed.

15-290 86E-7 – 98E-7 Series

Post treatment control FAILURE CODE (DTC) GENERAL DESCRIPTION

#B1445: —
Failure Failure phenomenon
#B1445 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. KDPF intermediate temperature sensor sys-
2. The recovery regeneration fails. tem
Injector
KDOC

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1.  KDPF intermediate temperature sensor system fault
2. KDOC deterioration or KDOC breakage due to the external factor such as sulfur poisoning
3. Injector defect
• Decrease in injection quantity
• Injection timing malfunction

 There are cases in which this error occurs due to the regeneration defect judgment caused by “KDPF intermediate
temperature sensor temperature abnormal low temperature”. When this is detected at the same time, be sure to per-
form the failure diagnosis for “KDPF intermediate temperature sensor temperature abnormal low temperature” in
advance.

86E-7 – 98E-7 Series 15-291

FAILURE CODE (DTC) GENERAL DESCRIPTION Post treatment control

#B1446: —
Failure Failure phenomenon
#B1446 —
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. SF
2. When recovery regeneration occurs, either of the following conditions is true:
• “KDPF PM accumulation density (C method)” is greater than or equal to the
threshold value of “PM accumulation density (for prohibition determination of
recovery regeneration)” and it continues for the time same to the “prohibition
determining time of recovery regeneration (C method)”.
• “KDPF PM accumulation density (P method)” is greater than or equal to the
threshold value of “PM accumulation density (for prohibition determination of
recovery regeneration)” and it continues for the time more than the “prohibi-
tion determining time of recovery regeneration (P method)”.

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

The PM is overaccumulated and the recovery regeneration cannot be performed.

15-292 86E-7 – 98E-7 Series

Others FAILURE CODE (DTC) GENERAL DESCRIPTION

Others

■ Overspeed

#B0219: Overspeed
Failure Failure phenomenon
#B0219 Overspeed
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Crank speed sensor
2. The engine speed is greater than the following threshold value. Cam speed sensor
• Maximum idling speed + 600 min-1 Injector
E-ECU

 Actions when a malfunction occurs

Fault mode [Engine stop]:
The engine operation stops.
Limited operation Yes: Fuel injection stops.
Reset criteria Yes: The fault mode is released when the ECU power off is detected.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Crank speed sensor fault
• Temporary failure caused by external factors such as radio waves
2. Cam speed sensor fault
• Temporary failure caused by external factors such as radio waves
3. E-ECU internal circuit fault
4. Injector failure

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display • Check the fault indication again by turning the ECU power ON and OFF.

 For details on the diagnosis method and procedure, see Chapter 16 P16-110.

86E-7 – 98E-7 Series 15-293

FAILURE CODE (DTC) GENERAL DESCRIPTION Others

■ Immobilizer

#BG167: Immobilizer CAN Communication Error

Failure Failure phenomenon
#BG167 Immobilizer CAN Communication Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Connector
2. Immobilizer communication error is detected. Harness
Machine controller
E-ECU

 Actions when a malfunction occurs

Fault mode Engine does not start
Limited operation
Reset criteria Yes: The fault mode is released when the E-ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Machine controller is replaced.
• This failure may result from replacement of machine controller.
2. Defective machine controller
• If this failure code appears while machine controller is not replaced, machine controller may be defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
3. Poor connection of the connector
4. Open-circuit or short-circuit of the wire harness
5. E-ECU internal fault

15-294 86E-7 – 98E-7 Series

Others FAILURE CODE (DTC) GENERAL DESCRIPTION

 Diagnosis
1. Initial diagnosis with the • Check the fault indication.
machine monitor display
 For details on the diagnosis method and procedure, see Chapter 16 P16-112.

2. Connector/wiring check • Before beginning your work, be sure to turn off the ECU power.
• Check the pin of the CAN communication connector for deformation and cracks, the condition
of the connection, and whether the retainer is loose or removed.
• Check whether the wiring of CAN communication connector is disconnected or the wiring coat-
ing is peeled.

3. Failure diagnosis • Check the conduction of the wire harness.

 For details on the diagnosis method and procedure, see Chapter 16 P16-112.

86E-7 – 98E-7 Series 15-295

FAILURE CODE (DTC) GENERAL DESCRIPTION Others

#BG426: Immobilizer System Error

Failure Failure phenomenon
#BG426 Immobilizer System Error
code (DTC) (Display of screen)

 DTC detection criteria

1. Prerequisite, 2. Judgment criteria Check points
1. No prerequisite. Machine controller
2. Immobilizer system error is detected. E-ECU

 Actions when a malfunction occurs

Fault mode Engine does not start
Limited operation
Reset criteria Yes: The fault mode is released when the E-ECU power is turned off.
Remarks

 Presumed cause of the malfunction or the abnormal condition

1. Malfunction of machine controller
(Since this is an internal defect, troubleshooting cannot performed.)
2. Malfunction of engine controller
(Since this is an internal defect, troubleshooting cannot performed.)

15-296 86E-7 – 98E-7 Series

 Section 16

METHOD AND PROCEDURE

OF FAILURE DIAGNOSIS
Page
Description ........................................................................................... 16-3
E-ECU pin layout diagram.............................................................. 16-4
How to use the Tier 4 checker harness.......................................... 16-6
Sensor related ...................................................................................... 16-7
Crank speed sensor ....................................................................... 16-7
Cam speed sensor ....................................................................... 16-10
Accelerator sensor ....................................................................... 16-14
Intake throttle position sensor ...................................................... 16-18
EGR low pressure side sensor..................................................... 16-21
EGR high pressure side sensor ................................................... 16-24
Cooling water temperature sensor ............................................... 16-27
New air temperature sensor ......................................................... 16-31
Fuel temperature sensor .............................................................. 16-35
Rail pressure sensor .................................................................... 16-39
KDPF differential pressure sensor ............................................... 16-42
KDPF inlet temperature sensor .................................................... 16-46
KDPF intermediate temperature sensor....................................... 16-50
EGR gas temperature sensor....................................................... 16-54
Intake manifold temperature sensor............................................. 16-58
Exhaust manifold temperature sensor.......................................... 16-62
Contact output related ........................................................................ 16-66
Main relay..................................................................................... 16-66
Startup assist relay (Glow relay) .................................................. 16-70
Contact input related .......................................................................... 16-74
Contact input related 1 ................................................................. 16-74
Contact input related 2 ................................................................. 16-78
CRS (common rail system) related .................................................... 16-81
Injector.......................................................................................... 16-81
Injector open circuit and coil short circuit................................. 16-81
Injector short circuit.................................................................. 16-85
High-pressure pump (MPROP) .................................................... 16-87

86E-7 – 98E-7 Series 16-1

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

Actuator...............................................................................................16-90
Intake throttle drive circuit .............................................................16-90
EGR valve .....................................................................................16-95
EGR valve .....................................................................................16-99
Communication related .....................................................................16-101
CAN1...........................................................................................16-101
CAN2...........................................................................................16-104
ECU related.......................................................................................16-107
Others ...............................................................................................16-110
Overspeed...................................................................................16-110
Immobilizer..................................................................................16-112

16-2 86E-7 – 98E-7 Series

Description METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

Description
 Related failure code (DTC)
The related failure code (DTC) are listed.

Failure 6-digit alphanumeric Failure phenomenon

Error name
code (DTC) character (Display of screen)

 Workflow
The workflow for failure diagnosis is listed.

 Wire diagram
The wire diagram for the parts related to faults is listed.

 Work description
The corrective action and procedure for failure diagnosis is listed.

86E-7 – 98E-7 Series 16-3

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Description

■ E-ECU pin layout diagram

Wire harness side coupler

(Connection surface)

A01 A02 – A04 A05 – A07 A08 – – A11 A12 – – A15 K01 K02 – – – – – – K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K26 K27 K28 1
A16 A17 – A19 A20 – – – – A25 A26 – A28 A29 A30 K29 – K31 K32 K33 – K35 K36 K37 K38 K39 K40 K41 K42 K43 K44 K45 K46 K47 K48 K49 K50 2
K03 K04
A31 A32 A33 A34 – – A37 A38 A39 – – – – – – K51 K52 K53 K54 K55 K56 – K58 – K60 K61 K62 K63 – K65 K66 K67 K68 K69 K70 K71 K72 3
– A47 – – A50 A51 A52 – A54 – – – – A59 A60 K05 K06 K73 K74 K75 K76 K77 – K79 K80 K81 – K83 K84 K85 K86 K87 K88B K89 K90 – K92 K93 K94 4

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z AA AB AC AD AE AF AG AH AI AJ AK AL AM

ECU side coupler

(Connection surface)

K28 K27 K26 K25 K24 K23 K22 K21 K20 K19 K18 K17 K16 K15 K14 K13 – – – – – – K02 K01 A15 – – A12 A11 – – A08 A07 – A05 A04 – A02 A01 1
K50 K49 K48 K47 K46 K45 K44 K43 K42 K41 K40 K39 K38 K37 K36 K35 – K33 K32 K31 – K29 A30 A29 A28 – A26 A25 – – – – A20 A19 – A17 A16 2
K04 K03
K72 K71 K70 K69 K68 K67 K66 K65 – K63 K62 K61 K60 – K58 – K56 K55 K54 K53 K52 K51 – – – – – – A39 A38 A37 – – A34 A33 A32 A31 3
K94 K93 K92 – K90 K89 K88B K87 K86 K85 K84 K83 – K81 K80 K79 – K77 K76 K75 K74 K73 K06 K05 A60 A59 – – – – A54 – A52 A51 A50 – – A47 – 4

AM AL AK AJ AI AH AG AF AE AD AC AB AA Z Y X W V U T S R Q P O N M L K J I H G F E D C B A
044375-00EN00

No. Terminal function name Code No. Terminal function name Code
A01 1-A Injector L INJL1 - 4 A54 4-I Crank speed CKSPD
Intake manifold temperature sen-
A02 1-B Injector L INJL1 - 4 A59 4-N TIAIR
sor
A04 1-D SCV H MPROP-H A60 4-O External 12 V UB2
A05 1-E SCV L HPPSOL K01 1-P VB VB
A07 1-G Sensor 5 V 5VS K02 1-Q ECU GND GND
A08 1-H Sensor 5 V 5VS K03 2-P VB VB
A11 1-K FO temperature sensor TFO K04 2-Q ECU GND GND
A12 1-L KDPF hi-side pressure sensor PDPFH K05 3-P VB VB
A15 1-O FO temperature sensor REOP2 K06 3-Q ECU GND GND
A16 2-A Injector L INJL1 - 4 K13 1-X Speed selection enable APP-IP6
A17 2-B Injector L INJL1 - 4 K14 1-Y Starter permission 1 APP-IP9
A19 2-D Intake valve motor IVDCM-H, L K15 1-Z LO pressure switch LOPSW
A20 2-E Intake valve motor IVDCM-H, L K16 1-AA Speed 2 APP-IP4
A25 2-J Analog GND A-GND K17 1-AB Hi-idle speed select APP-IP8
A26 2-K Rail pressure PRAIL K18 1-AC KDPF regeneration request REGSW
A28 2-M CW temperature sensor TW K19 1-AD Speed 1 APP-IP3
A29 2-N Analog GND A-GND K20 1-AE Intake valve sensor IVPS
A30 2-O External 12 V UB5 K21 1-AF Analog GND A-GND
A31 3-A Injector H INJH1 - 4 K22 1-AG Accelerator pedal PDLSW
A32 3-B Injector H INJH1 - 4 K23 1-AH Sensor 5 V 5VS
A33 3-C Injector H INJH1 - 4 K24 1-AI Sensor 5 V 5VS
A34 3-D Reserve REOP1 K25 1-AJ KDPF regeneration request DPF-M1
A37 3-G Cam speed CMSPD K26 1-AK Iso-chronous lamp APP-OP2
A38 3-H Analog GND A-GND K27 1-AL KDPF regeneration inhibit lamp DPF-M2

16-4 86E-7 – 98E-7 Series

Description METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

No. Terminal function name Code No. Terminal function name Code
A39 3-I Crank speed CKSPD K28 1-AM Starter relay STR-RLY
A47 4-B Injector H INJH1 - 4 K29 2-R External 12 V UB2
A50 4-E External 12 V UB3 K31 2-T KDPF regeneration inhibit REGMSW
A51 4-F Analog GND A-GND K32 2-U Engine stop 1 SHUDNSW
A52 4-G Analog GND A-GND K33 2-V EGR gas temperature sensor TEGR
K35 2-X Key switch start STARTSW K67 3-AH Engine stop 2 APP-IP7
K36 2-Y Reserve analog REAN K68 3-AI External 12 V UB2
K37 2-Z Droop APP-IP1 K69 3-AJ EGT lamp DPF-M3
K38 2-AA Starter permission 2 APP-IP2 K70 3-AK Starting aid relay SAID-RLY
KDPF regeneration acknowledge
K39 2-AB EGR low-side pressure sensor PEGRL K71 3-AL DPF-M4
lamp
K40 2-AC Water separator sensor WSSW K72 3-AM Amber warning lamp REOP3
K41 2-AD Air cleaner sensor ACLSW K73 4-R External 12 V UB5
K42 2-AE Hi-idle limit enable APP-IP5 K74 4-S Analog GND A-GND
K43 2-AF Sensor 5 V 5VS K75 4-T CAN-H2 CAN2H
K44 2-AG Sensor 5 V 5VS K76 4-U CAN-L1 CAN1L
K45 2-AH Sensor 5 V 5VS K77 4-V Analog GND A-GND
K46 2-AI Sensor 5 V 5VS K79 4-X Fresh air temperature sensor TFAIR
K47 2-AJ Load ratio monitor LOAD-M K80 4-Y KDPF inside temperature sensor TDPFM
K48 2-AK Red engine stop lamp REOP4 K81 4-Z KDPF inlet temperature sensor TDPFI
K49 2-AL CWT warning lamp OVHT-LMP K83 4-AB Accelerator sensor 2 APS2
K50 2-AM Pre-heat lamp PREHT-LMP K84 4-AC Analog GND A-GND
K51 3-R External 12 V UB3 K85 4-AD EGR hi-side pressure sensor PEGR
K52 3-S Analog GND A-GND K86 4-AE Regeneration interlock WDSBSW
K53 3-T CAN-L2 CAN2L K87 4-AF Analog GND D-GND
K54 3-U CAN-H1 CAN1H K88B 4-AG Key switch on IGNSW
K55 3-V Analog GND A-GND K89 4-AH External 12 V UB3
K56 3-W Exhaust gas temperature sensor TEXMN K90 4-AI External 12 V UB3
K58 3-Y Accelerator sensor 3 APS3 K92 4-AK Failure lamp FAIL-LMP
K60 3-AA Analog GND A-GND K93 4-AL Speed selection lamp APP-OP1
K61 3-AB Accelerator sensor 1 APS1 K94 4-AM Speed monitor NRPM-M
K62 3-AC Analog GND A-GND
KDPF differential pressure sen-
K63 3-AD PDPF
sor
K65 3-AF Analog GND D-GND
K66 3-AG Alternator L terminal CHGSW

86E-7 – 98E-7 Series 16-5

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Description

■ How to use the Tier 4 checker harness

When you perform the E-ECU related failure diagnosis, use the Tier 4 checker harness (YM129A00-91080) to mea-
sure the voltage value. Therefore, remove the E-ECU and the machine wire harness and connect the Tier 4 checker
harness between the E-ECU and the machine wire harness prior to the failure diagnosis.
Note • For the details of the failure diagnosis on each part, refer to the following description.
• Use the circuit tester to measure the voltage value in accordance with the following table as a reference.

Tier 4 checker harness

Check!
A01AA02A A04A A05A A07A A08A A11A A12AA15A
A16A A17A A18A A19A A20A A25A A26A A28A
K01A K02A K03A K04A K05A K06A K13A K14A K15A A29A A30AA31A A32A A33A A34A A37A A38A
K16A K17A K18A K19A K20A K21A K22A K23A A39AA47A A48A A50A A51A A52A A54A A59A A60A
K24A K25A K26A K27A K28A K29A K31A K32A
K33A K35A K36A K37A K38A K39A K40A K41A K42A

K43A K44A K45A K46A K47AK48A K49A K50A K51A

Machine wire
K52A K53A K54AK55A K56A K57A K58A K60A
K61A K62A K63AK65A K66A K67A K68A K69A
K70A K71A K72A K73A K74A K75A K76A K77A K79A

K80A K81A K83A K84A K85A K86A K87A

K88A K89A K90A K92A K93A K94A
E-ECU
-- -- -- -- -- --
-- -- -- -- -- -- --

K90B --
K75B --
K53B K65B

Connect between the E-ECU

Machine

With the circuit tester,

measure the voltage value
between the
specified terminals.

E-ECU
050957-00EN00

16-6 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

Sensor related

■ Crank speed sensor

 Related DTC
Failure Failure phenomenon
#B0336 Crank Signal Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0337 No Crank Signal
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0008 No Signal on Both Crank and Cam Speed Sensor
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”.
ࠋ
Initial diagnosis by the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault

Currently trouble is occurring

Failure diagnosis

1. Check the crank No

speed sensor resistance Replace the sensor
value (Sensor)

OK
Replace the sensor
or
2. Check the crank replace the harness
speed sensor resistance No
value (sensor + harness)

OK Replace the harness

or
replace the E-ECU
OK
3. Check the pulser

No Correct the faulty part

045705-00EN00

86E-7 – 98E-7 Series 16-7

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Wire diagram

Crank speed sensor Junction coupler E-ECU

1 2
B
CKSPD
A39

A A54
CKSPD

A38
A_GND

Wire harness side coupler

(welding surface)

Shielding wire

A54 A39
O P

1 2
Sensor side junction coupler E-ECU side junction coupler
(connection surface) (connection surface)

A39 A54 A54 A39

: Check points
045706-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

16-8 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Checking the crank speed sensor resistance value (sensor):
1- Remove the wire harness from the accelerator speed sensor.
2- Use the circuit tester to measure the resistance value between the crank speed sensors A and B.
Reference: The resistance value between the crank speed sensor terminals

Terminal Specification
Sensor A - B 1050 Ω (Error 10 %)

Not OK Replace the crank speed sensor.

OK Refer to “Checking the crank speed sensor resistance value (sensor + harness):”

2. Checking the crank speed sensor resistance value (sensor + harness):

1- Remove the E-ECU from the harness while the crank speed sensor and the harness are connected.
2- Use the circuit tester to measure the resistance value between the harness side E-ECU connector terminals
A39 - A54.
Note: Refer to the above-mentioned reference “The resistance value between the crank speed sensor termi-
nals”.

• The coupler between the sensor and the wire harness may be defective. Replace the sensor.
Not OK
• Replace the wire harness.
OK Refer to “Checking the pulser:”

3. Checking the pulser:

1- Check the pulser condition (cracks, metallic sticking, and distortion).

Not OK Correct the faulty parts.

• A coupler failure between the E-ECU and the harness may be caused. Replace the wire harness.
OK
• Replace the E-ECU.

86E-7 – 98E-7 Series 16-9

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

■ Cam speed sensor

 Related DTC
Failure Failure phenomenon
#B0341 Cam Signal Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0342 No Cam Signal
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0008 No Signal on Both Crank and Cam Speed Sensor
code (DTC) (Display of screen)

16-10 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Workflow
Note: For the details of work, refer to the following “Work description”.

ࠋ
Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication
There is a
current fault

Current fault is occurring

Failure diagnosis operation

1. Replacing the cam speed sensor

Turn on and off the power switch

2. The same work as There is not a current fault

the above initial diagnosis Normal

There is a current fault

No Replace the
3. Wire harness conduction
check (wire harness) wire harness

Replace the
OK
wire harness
or
OK replace the E-ECU
3. Check the pulser

No Correct the faulty part

045707-00EN00

86E-7 – 98E-7 Series 16-11

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Wire diagram

Cam speed sensor E-ECU

Junction coupler
1 2
C A08
5VS

B A37
CMSPD

A A52
A-GND

Wire harness side coupler

(welding surface)

A52 A37 A08

1 2
Sensor side junction coupler E-ECU side junction coupler
(connection surface) (connection surface)

A08 A37 A52 A52 A37 A08

: Check points
045708-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

16-12 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Replacing the cam speed sensor:
1- Remove and replace the cam speed sensor from the wire harness.

2. Using the machine monitor:

1- Turn off the power switch. Turn on the power switch and start the engine.
2- Check if any error is detected and indicated at present by the failure display of the machine monitor.

No Normal
Applied Refer to “Check the wire harness conduction:”

3. Check the wire harness conduction:

1- Remove the wire harness from the cam speed sensor and the E-ECU. Here, keep the junction coupler con-
nected.
2- Perform the wire harness conduction check between the terminal 1 and the terminal 2 in the below table while
referring to P16-4 "E-ECU pin layout diagram".
Reference: Cam speed sensor conduction check pattern 1

Terminal 2 (cam speed

Terminal 1 (E-ECU side
sensor side wire harness Conduction Condition
wire harness connector)
connector)
Cam speed sensor Yes Not OK: Abnormal
A08
terminal C No OK: Normal
Cam speed sensor Yes Not OK: Abnormal
A37
terminal B No OK: Normal
Cam speed sensor Yes Not OK: Abnormal
A52
terminal A No OK: Normal

Reference: Cam speed sensor conduction check pattern 2

Terminal 1 (E-ECU side Terminal 2 (E-ECU side

Conduction Condition
wire harness connector) wire harness connector)
Yes Not OK: Abnormal
A08
No OK: Normal
Yes Not OK: Abnormal
A37 All other terminals
No OK: Normal
Yes Not OK: Abnormal
A52
No OK: Normal

Not OK Interrupted or short circuited between the wire harnesses. Replace the wire harness.
OK Refer to “Checking the pulser:”

4. Checking the pulser:

1- Check the pulser condition (cracks, metallic sticking, and distortion).

Not OK Correct the faulty parts.

• Replace the wire harness.
OK
• Replace the E-ECU.

86E-7 – 98E-7 Series 16-13

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

■ Accelerator sensor
 Related DTC
Failure Failure phenomenon
#B0123 Accelerator Sensor 1 (High voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0122 Accelerator Sensor 1 (Low voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0223 —
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0222 —
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0228 Accelerrator sensor 3 (Excessive sensor output)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0227 Accelerrator sensor 3 (Insufficient sensor output)
code (DTC) (Display of screen)

16-14 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Workflow
Note: For the work details, refer to “Work description” below.

ࠋ
Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault [Check Item]:
Accelerator sensor position (%) “Signal Data (SD)”
B. Failure presumption SD 250 (0.25 V) Short circuit of signal wire GND?
by checking the 4700 (4.7 V) SD Open circuit?
detection value

Failure diagnosis

1. Check the sensor No

resistance value Replace the sensor
(sensor unit)

OK
Replace the sensor
or
2. Check the sensor No replace the harness
resistance value
(sensor + harness)

OK Replace the harness

or
replace the E-ECU
3. Check the accelerator No
sensor output voltage

OK Replace the E-ECU

043556-01E00

86E-7 – 98E-7 Series 16-15

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Wiring diagram

Accelerator sensor 1 (option) E-ECU

C K43
Sensor side coupler A-VCC10
(welding surface)

C B A B K61
APS1

A K62
A-GND10

Wire harness side coupler

(welding surface)

K62 K61 K43

B P R

Accelerator sensor 2 (option)

F K46
A-VCC11

E K83
APS2
Wire harness side coupler
(welding surface)
D K84
A-GND11
K84 K83 K46
Y G L
Accelerator sensor 3 (option)
I K44
A-VCC12

H K58
APS3

G K55
A-GND12

Wire harness side coupler

(welding surface)

K22
K55 K58 K44 PDLSW
B O R
K22 K89
P R Backup accelerator sensor (option)
K89

V70
REAN

: Check points

043363-01EN02

Note: For the E-ECU pin layout, refer to P16-4.

16-16 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Checking the sensor resistance value (sensor unit):
 Between the accelerator sensor1 terminals A and C (accelerator sensor2 terminals D and F) (accelerator sen-
sor3 terminals G and I) (total resistance value)
1- Remove the wire harness from the accelerator sensor.
2- Use the circuit tester to measure the resistance value (total resistance value) between the sensor terminals A
and C (D and F) (G and I).
Reference: Total resistance value of the standard accelerator sensor

Terminal Failure phenomenon (Display of screen)

Sensor A - C (D - F) 5 ± 1.5 kΩ

Not OK Replace the accelerator sensor.

OK Refer to “Between the accelerator sensor terminals A and B (D and E) (G and H)”

 Between the accelerator sensor terminals A and B (D and E) (G and H)

1- Use the circuit tester to measure the resistance value between the accelerator sensor terminals A and B (D
and E) (G and H).
2- Move the acceleration throttle to check whether or not the resistance value between the accelerator sensor
terminals A and B changes.

Not OK Replace the accelerator sensor.

OK Refer to “Checking the sensor resistance value (sensor + wire harness):”

2. Checking the sensor resistance value (sensor + wire harness):

 Between the wire harnesses K43 and K62 (K46 and K84) (K44 and K55) (total resistance value)
1- Connect the accelerator sensor and the wire harness. Remove the wire harness from the E-ECU.
2- Use the circuit tester to measure the resistance value (total resistance value) between the wire harness side
E-ECU connectors K43 and K62 (K46 and K84) (K44 and K55).
Note: Refer to the above-mentioned reference “Total resistance value of the standard accelerator sensor”.

• A coupler failure between the sensor and the wire harness may be caused. Replace the sensor.
Not OK
• Replace the wire harness.
OK Refer to “Between the wire harnesses K61 and K62 (K83 and K84) (K58 and K55)”

 Between the wire harnesses K61 and K62 (K83 and K84) (K58 and K55)
1- Use the circuit tester to measure the resistance value between the E-ECU connectors K61 - K62 (K83 - K84)
(K58 - K55).
2- Move the acceleration throttle to check whether or not the resistance value between the E-ECU connectors
K61 - K62 (K83 - K84) (K58 - K55) changes.

• A coupler failure between the sensor and the wire harness may be caused. Replace the sensor.
Not OK
• Replace the wire harness.
OK Refer to “Check the output voltage of the accelerator sensor:”

86E-7 – 98E-7 Series 16-17

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

■ Intake throttle position sensor

 Related DTC
Failure Failure phenomenon
#B02E8 Intake Throttle Open Position Sens Error (Low V)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B02E9 Intake Throttle Open Position Sens Error (High V)
code (DTC) (Display of screen)

 Workflow
Note: For the work details, refer to “Work description” below.
ࠋ
Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault [Check Item]:
intake throttle position sensor “Signal Data (SD)”
B. Failure presumption SD ” 200 (0.2 V) Short circuit of signal
by checking the wire GND?
detection value 4800 (4.8 V) ” SD Open circuit?

Failure diagnosis operation

1. Check the E-ECU

output voltage No Replace the harness
(E-ECU + harness + sensor) or
replace the E-ECU

OK

Turn the power switch ON/OFF after

2. Check the output correcting the failure
voltage of intake throttle position No
sensor (E-ECU +
sensor + harness)
There is no current fault

OK 3. This is the same

operation as the above Normal
initial diagnosis
Replace the E-ECU

There is a
current fault

Replace the intake throttle

position sensor

050230-00EN00

16-18 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Wiring diagram

Junction coupler
Intake throttle position sensor E-ECU
E 1 2 A19
IVDCM-H

D A20
IVDCM-L

C K23
A-VCC12

B K20
IVPS

A K52
A-GND12

Sensor side coupler Wire harness side coupler

(welding surface) (welding surface)

B C A E D

A20 A19 K52 – K23 K20

L Y Br B G

1 Sensor side junction coupler 2 E-ECU side junction coupler

(connection surface) (connection surface)

K52 A19 A20 K23 K20 K20 K23 A20 A19 K52

: Check points
050240-00EN01

Note: For the E-ECU pin layout, refer to P16-4.

86E-7 – 98E-7 Series 16-19

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Work description
1. Check the E-ECU output voltage:
1- Connect the checker wire harness between the E-ECU and the wire harness on the equipment. Also, connect
all connectors (sensors and wire harness E-ECU).
2- Use the circuit tester to measure the voltage value between the intake throttle position sensor 5 V K23 - K52.

Voltage value Condition Corrective action

• Replace the wire harness.
K23 < 4.375 V Not OK
• Replace the E-ECU.
4.375 V K23 5.625 V OK (Normal range) Check the output voltage of the intake throttle position sensor.
• Replace the wire harness.
5.625 V < K23 Not OK
• Replace the E-ECU.

Replace the wire harness or the E-ECU. Turn the power switch OFF/ON and perform the diagnosis
Not OK
using the machine monitor.
OK Refer to “Check the output voltage of the intake throttle position sensor:”

2. Check the output voltage of the intake throttle position sensor:

1- Connect the checker wire harness between the E-ECU and the wire harness on the equipment. Also, connect
all connectors (sensors and wire harness E-ECU).
2- Use the circuit tester to measure the voltage value between the sensor signals K20 - K52.

Voltage value Condition Corrective action

• Replace the wire harness.
K20 < 0.2 V Not OK
• Replace the E-ECU.
0.2 V K20 4.8 V OK (Normal range) Replace the E-ECU.
• Replace the wire harness.
4.8 V < K20 Not OK
• Replace the E-ECU.

Replace the wire harness or the E-ECU. Turn the power switch OFF/ON and perform the diagnosis
Not OK
using the machine monitor.
OK Replace the E-ECU.

3. Using the machine monitor.

1- Turn off the power switch. Turn on the power switch and start the engine.
2- Check if any error is detected and indicated at present by the failure display of the machine monitor.

No Normal
Applied Replace the intake throttle position sensor.

16-20 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

■ EGR low pressure side sensor

 Related DTC
Failure Failure phenomenon
#B0238 EGR Low Pressure Side Sensor Error (High Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0237 EGR Low Pressure Side Sensor Error (Low Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0236 EGR Low Pres Side Sens Error (Abnorm Learn Value)
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault
indication condition

There is a
current fault [Check item] : EGR low side pressure on the
Diag. Test screen
B. Presumed cause · Less than 0.2 V э Open circuit or GND short-circuit of
after checking the signal wire?
detection value · Larger than 4.8 V э VB short-circuit of signal wire?

Failure diagnosis

1. Cable check of the No Replace the

EGR low pressure wire harness
sensor wiring

OK
Replace the EGR
2. Check of the output pressure sensor
voltage of the EGR low No
pressure sensor (sensor
+ wire harness)
OK Replace the E-ECU

050736-00EN00

86E-7 – 98E-7 Series 16-21

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Wire diagram

EGR pressure sensor E-ECU

D K74
AGND

C K45
5VS

B K39
PEGRL

A K85
PEGR

Wire harness side coupler

(welding surface)

– K85 K39 K45 K74 –

: Check points

050737-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

16-22 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Cable check of the EGR low pressure sensor wiring:
1- Remove the wire harness from the EGR pressure sensor and the E-ECU.
2- Using the circuit tester, check the cable of the wire harness.

Terminal Cable check Condition

OK Normal
Between B and K39
Not OK Wire harness failure
OK Normal
Between C and K45
Not OK Wire harness failure
OK Normal
Between D and K74
Not OK Wire harness failure

• Check if the wire harness is damaged or there is mis-wiring.

Not OK
• Replace the wire harness.
OK Refer to “Check of the output voltage of the EGR low pressure sensor. (sensor + wire harness):”

2. Check of the output voltage of the EGR low pressure sensor. (sensor + wire harness):
1- Connect the checker harness between the E-ECU and the machine wire harness. Also, connect all connec-
tors (sensor and E-ECU).
2- Using the circuit tester, measure the voltage value between the EGR low pressure sensor signals K39 and
K74.

Voltage value State Treatment

• Replace the wire harness.
K39 < 0.2 V Not OK
• Replace the E-ECU.
OK
0.2 V  K39  4.8 V Replace the E-ECU.
(Normal range)
• Replace the wire harness.
4.8 V < K39 Not OK
• Replace the E-ECU.

Not OK Replace the EGR pressure sensor. Then, check the output voltage again.
OK Replace the E-ECU.

86E-7 – 98E-7 Series 16-23

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

■ EGR high pressure side sensor

 Related DTC
Failure Failure phenomenon
#B0473 EGR High Pressure Side Sensor Error (High Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0472 EGR High Pressure Side Sensor Error (Low Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0471 EGR High Pres Side Sens Error (Abnorm Learn Value)
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault
indication condition

There is a
current fault [Check item] : EGR high side pressure on the
Diag. Test screen
B. Presumed cause · Less than 0.2 V э Open circuit or GND short-circuit of
after checking the signal wire?
detection value · Larger than 4.8 V э VB short-circuit of signal wire?

Failure diagnosis

1. Cable check of the No Replace the

EGR high pressure wire harness
sensor wiring

OK
Replace the EGR
2. Check of the output pressure sensor
voltage of the EGR high No
pressure sensor (sensor
+ wire harness)
OK Replace the E-ECU

050738-00EN00

16-24 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Wire diagram

EGR pressure sensor E-ECU

D K74
AGND

C K45
5VS

B K39
PEGRL

A K85
PEGR

Wire harness side coupler

(welding surface)

– K85 K39 K45 K74 –

: Check points

050737-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

86E-7 – 98E-7 Series 16-25

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Work description
1. Cable check of the EGR high pressure sensor wiring:
1- Remove the wire harness from the EGR pressure sensor and the E-ECU.
2- Using the circuit tester, check the cable of the wire harness.

Terminal Cable check Condition

OK Normal
Between A and K85
Not OK Wire harness failure
OK Normal
Between C and K45
Not OK Wire harness failure
OK Normal
Between D and K74
Not OK Wire harness failure

• Check if the wire harness is damaged or there is mis-wiring.

Not OK
• Replace the wire harness.
OK Refer to “Check of the output voltage of the EGR high pressure sensor. (sensor + wire harness):”

2. Check of the output voltage of the EGR high pressure sensor. (sensor + wire harness):
1- Connect the checker harness between the E-ECU and the machine wire harness. Also, connect all connec-
tors (sensor and E-ECU).
2- Using the circuit tester, measure the voltage value between the EGR high pressure sensor signals K85 and
K74.

Voltage value State Treatment

• Replace the wire harness.
K85 < 0.2 V Not OK
• Replace the E-ECU.
OK
0.2 V  K85  4.8 V Replace the E-ECU.
(Normal range)
• Replace the wire harness.
4.8 V < K85 Not OK
• Replace the E-ECU.

Not OK Replace the EGR pressure sensor. Then, check the output voltage again.
OK Replace the E-ECU.

16-26 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

■ Cooling water temperature sensor

 Related DTC
Failure Failure phenomenon
#B0117 Cooling Water Temperature Sensor Error (Low Volt)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0118 Cooling Water Temperature Sens Error (High Volt)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0217 —
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault
indication condition

There is a
current fault [Check item] : Cooling water temperature on the
Diag. Test screen
B. Presumed cause · Less than 0.2 V э GND short circuit of the sensor
after checking the signal wire?
detection value · Larger than 4.8 V э Open circuit?

Failure diagnosis

1. Check of the sensor No

resistance value Replace the sensor
(sensor unit)

OK Replace the sensor

or
2. Check of the sensor replace the
No
resistance value wire harness
(sensor + wire harness)

Replace the
OK
wire harness
or
3. Check of the output No replace the E-ECU
voltage of the cooling water
temperature sensor
OK Replace the E-ECU

044383-01EN00

86E-7 – 98E-7 Series 16-27

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Sensor diagram

039875-00EN02

 Wire diagram

Cooling water Junction coupler

temperature sensor E-ECU
1 2
A A28
TW

B A29
A-GND

Wire harness side coupler

(welding surface)

A28 A29

1 2
Sensor side junction coupler E-ECU side junction coupler
(connection surface) (connection surface)

A28 A29
A29 A28

: Check points
044377-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

16-28 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Check of the sensor resistance value (sensor unit):
1- Remove the wire harness from the cooling water temperature sensor.
2- Using the circuit tester, measure the resistance value between the cooling water temperature sensor terminals
A and B.
3- Refer to the following diagram “Cooling water temperature sensor characteristics” to check that the measured
resistance value is in the normal range.
Cooling water temperature sensor characteristics

Relationship between the cooling water temperature

and the sensor resistance value
140
7HPS ƒ& 5HVLVWDQFH Nȍ
-30 25.4
120 -20 15.04
-10 9.16
100 0 5.74
10 3.7

80 20 2.45
30 1.66
7HPSHUDWXUH ƒ&

40 1.15
60
50 0.811
60 0.584
40 70 0.428
80 0.318
20 90 0.24
100 0.1836
110 0.1417
0
120 0.1108

-20

-40
0 5 10 15 20 25 30
6HQVRUUHVLVWDQFHYDOXH Nȍ 044402-00EN00

Not OK Replace the cooling water temperature sensor.

OK Refer to “Check of the sensor resistance value (sensor + wire-harness):”

86E-7 – 98E-7 Series 16-29

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

2. Check of the sensor resistance value (sensor + wire-harness):

1- Connect the cooling water temperature sensor and the wire harness and remove the E-ECU from the wire
harness.
2- Using the circuit tester, measure the resistance value between the wire harness side E-ECU connector termi-
nals A28 and A29.
3- Refer to the above diagram “Cooling water temperature sensor characteristics” to check that the measured
resistance value is in the normal range.

• The coupler between the sensor and the wire harness may be defective. Replace the sensor.
Not OK
• Replace the wire harness.
OK Refer to “Check of the output voltage of the cooling water temperature sensor:”

3. Check of the output voltage of the cooling water temperature sensor:

1- Connect the checker harness between the E-ECU and the machine wire harness. Also, connect all connec-
tors (sensor and E-ECU).
2- Using the circuit tester, measure the voltage value between the cooling water temperature sensor signals A28
and A29.

Voltage value State Treatment

• Replace the wire harness.
A28 < 0.2 V Not OK
• Replace the E-ECU.
OK
0.2 V  A28  4.8 V Replace the E-ECU.
(Normal range)
• Replace the wire harness.
4.8 V < A28 Not OK
• Replace the E-ECU.

• The coupler between the wire harness and the ECU may be defective. Replace the wire harness.
Not OK
• Replace the E-ECU.
OK Replace the E-ECU.

16-30 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

■ New air temperature sensor

 Related DTC
Failure Failure phenomenon
#B0112 New Air Temperature Sensor Error (Low Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0113 New Air Temperature Sensor Error (High Voltage)
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault
indication condition

There is a
current fault [Check item] : New air temperature sensor on the
Diag. Test screen
B. Presumed cause · Less than 0.2 V э GND short circuit of the sensor
after checking the signal wire?
detection value · Larger than 4.8 V э Open circuit?

Failure diagnosis

1. Check of the sensor No

resistance value Replace the sensor
(sensor unit)

OK Replace the sensor

or
2. Check of the sensor replace the
No wire harness
resistance value
(sensor + wire harness)

OK Replace the
wire harness
or
3. Check of the output No replace the E-ECU
voltage of the new air
temperature sensor
OK Replace the ECU

044384-01EN00

86E-7 – 98E-7 Series 16-31

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Wire diagram

Junction coupler
E-ECU
1 2
A K79
TFAIR
New air
temperature
sensor
B K21
A-GND

Wire harness side coupler

(welding surface)

K79 K21

1 2
Sensor side junction coupler E-ECU side junction coupler
(connection surface) (connection surface)

K79 K21
K21 K79

: Check points
044378-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

16-32 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Check of the sensor resistance value (sensor unit):
1- Remove the wire harness from the new air temperature sensor.
2- Using the circuit tester, measure the resistance value between the new air temperature sensor terminals A
and B.
3- Refer to the following diagram “New air temperature sensor characteristics” to check that the measured resis-
tance value is in the normal range.
New air temperature sensor characteristics

Relation between ambient temperature and sensor resistance value

160
5HVLVWDQFH ȍ
140 Temp. (°C) Min. Typ. Max.
-40 40720 43318 45918
120 0 5417 5652 5886
25 1940 2000 2060
100 50 783.6 812.8 842.1
80 100 177.1 186 194.4
Temperature (°C)

150 54.48 57.96 61.44

60

40

20

0
Typ. Max.
-20

-40
Min.
-60
0 10000 20000 30000 40000 50000
6HQVRUUHVLVWDQFHYDOXH ȍ 044398-00EN01

Not OK Replace the new air temperature sensor.

OK Refer to “Check of the sensor resistance value (sensor + wire-harness):”

2. Check of the sensor resistance value (sensor + wire-harness):

1- Connect the new air temperature sensor and the wire harness and remove the E-ECU from the wire harness.
2- Using the circuit tester, measure the resistance value between the E-ECU side wire harness connector termi-
nals K79 and K21.
3- Refer to the above diagram “New air temperature sensor characteristics” to check that the measured resis-
tance value is in the normal range.

• The coupler between the sensor and the wire harness may be defective. Replace the sensor.
Not OK
• Replace the wire harness.
OK Refer to “Check of the output voltage of the new air temperature sensor:”

86E-7 – 98E-7 Series 16-33

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

3. Check of the output voltage of the new air temperature sensor:

1- Connect the checker harness between the E-ECU and the machine wire harness. Also, connect all connec-
tors (sensor and E-ECU).
2- Using the circuit tester, measure the voltage value between the new air temperature sensor signals K79 and
K21.

Voltage value State Treatment

• Replace the wire harness.
K79 < 0.15 V Not OK
• Replace the E-ECU.
OK
0.15 V  K79  4.85 V Replace the E-ECU.
(Normal range)
• Replace the wire harness.
4.85 V < K79 Not OK
• Replace the E-ECU.

• The coupler between the wire harness and the ECU may be defective. Replace the wire harness.
Not OK
• Replace the E-ECU.
OK Replace the E-ECU.

16-34 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

■ Fuel temperature sensor

 Related DTC
Failure Failure phenomenon
#B0182 Fuel Temperature Sensor Error (Low Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0183 Fuel Temperature Sensor Error (High Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0168 Fuel Temperature Sensor Temperature Abnormal High
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”.

ࠋ
Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication
There is a
current fault [Check item]: Fuel temperature sensor on the Diag.
Test screen
B. Presumed cause · SD < less than 100 (0.1 V) 0.2 V э Short circuit of
after checking the signal wire GND?
detection value · 4800 (4.8 V) < larger than SD 4.8 V э Open circuit?

Failure diagnosis

1. Check of the sensor No

resistance value Replace the sensor
(sensor unit)

OK Replace the sensor

or
2. Check of the sensor replace the
No wire harness
resistance value
(sensor + wire harness)

OK Replace the
wire harness
or
3. Check of the output No replace the E-ECU
voltage of the fuel
temperature sensor
OK Replace the E-ECU

044385-01EN00

86E-7 – 98E-7 Series 16-35

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Wire diagram

Exhaust air temperature sensor

Junction coupler
E-ECU
A 1 2

B K56
TEXMN

Fuel temperature sensor

A A11
TFO

B
A51
A-GND

Wire harness side coupler

(welding surface)

A11 A51

1 2
Sensor side junction coupler E-ECU side junction coupler
(connection surface) (connection surface)

A11 A51
A51 A11

: Check points
044379-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

16-36 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Check the sensor resistance value (sensor unit):
1- Remove the wire harness from the fuel temperature sensor.
2- Using the circuit tester, measure the resistance value between the fuel temperature sensor terminals A and B.
3- Refer to the following diagram “Fuel temperature sensor characteristics” to check that the measured resis-
tance value is in the normal range.
Fuel temperature sensor characteristics

Relationship between the fuel temperature and the sensor resistance value
160
Temp. (°C) 5HVLVWDQFH>Nȍ@
140 -40 45.313
120 -20 15.462
-10 9.397
100
0 5.896
80
Temperature (°C)

20 2.5
60 25 2.057
㩷 40 1.175
40
60 0.596
20
80 0.323
0
100 0.186
-20 120 0.113

-40 140 0.071

150 0.057
-60
0 10 20 30 40 50
6HQVRUUHVLVWDQFHYDOXH Nȍ 044399-00EN00

Not OK Replace the fuel temperature sensor.

OK Refer to “Check of the sensor resistance value (sensor + wire-harness):”

2. Check of the sensor resistance value (sensor + wire-harness):

1- Connect the fuel temperature sensor and the wire harness and remove the E-ECU from the wire harness.
2- Using the circuit tester, measure the resistance value between the wire harness side E-ECU connector termi-
nals A11 and A51.
3- Refer to the below diagram “Fuel temperature sensor characteristics” to check that the measured resistance
value is in the normal range.

• The coupler between the sensor and the wire harness may be defective. Replace the sensor.
Not OK
• Replace the wire harness.
OK Refer to “Check of the output voltage of the fuel temperature sensor:”

86E-7 – 98E-7 Series 16-37

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

3. Check of the output voltage of the fuel temperature sensor:

1- Connect the checker harness between the E-ECU and the machine wire harness. Also, connect all connec-
tors (sensor and E-ECU).
2- Using the circuit tester, measure the voltage value between the sensor signals A11 and A51.

Voltage value State Treatment

• Replace the wire harness.
A11 < 0.2 V Not OK
• Replace the E-ECU.
OK
0.2 V  A11  4.8 V Replace the E-ECU.
(Normal range)
• Replace the wire harness.
4.8 V < A11 Not OK
• Replace the E-ECU.

• The coupler between the fuel temperature sensor and the E-ECU may be defective. Replace the wire
Not OK harness.
• Replace the E-ECU.
OK Replace the E-ECU.

16-38 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

■ Rail pressure sensor

 Related DTC
Failure Failure phenomenon
#B0193 Rail Pressure Sensor Error (High Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0192 Rail Pressure Sensor Error (Low Voltage)
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault
indication condition

There is a
current fault [Check item] : EGR high side pressure on the
Diag. Test screen
B. Presumed cause · Less than 0.2 V э Open circuit or GND short-circuit of
after checking the signal wire?
detection value · Larger than 4.8 V э VB short-circuit of signal wire?

Failure diagnosis

1. Cable check of the No Replace the

EGR high pressure wire harness
sensor wiring

OK
Replace the EGR
2. Check of the output pressure sensor
voltage of the EGR high No
pressure sensor (sensor
+ wire harness)
OK Replace the E-ECU

050738-00EN00

86E-7 – 98E-7 Series 16-39

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Wire diagram

Rail pressure sensor E-ECU

C A07
5VS

B A26
PRAIL

A A25
A_GND

Wire harness side coupler

(welding surface)

A25 A26 A07

: Check points
050749-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

16-40 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Cable check of the rail pressure sensor wiring:
1- Remove the wire harness from the rail pressure sensor and the E-ECU.
2- Using the circuit tester, check the cable of the wire harness.

Terminal Cable check Condition

OK Normal
Between A and A25
Not OK Wire harness failure
OK Normal
Between B and A26
Not OK Wire harness failure
OK Normal
Between C and A07
Not OK Wire harness failure

• Check if the wire harness is damaged or there is mis-wiring.

Not OK
• Replace the wire harness.
OK Refer to “Check of the output voltage of the rail pressure sensor. (sensor + wire harness):”

2. Check of the output voltage of the rail pressure sensor. (sensor + wire harness):
1- Connect the checker harness between the E-ECU and the machine wire harness. Also, connect all connec-
tors (sensor and E-ECU).
2- Using the circuit tester, measure the voltage value between the rail pressure sensor signals A26 and A25.

Voltage value State Treatment

• Replace the wire harness.
A26 < 0.24 V Not OK
• Replace the E-ECU.
OK
0.24 V  A26  4.75 V Replace the E-ECU.
(Normal range)
• Replace the wire harness.
4.75 V < A26 Not OK
• Replace the E-ECU.

Not OK Replace the rail pressure sensor. Then, check the output voltage again.
OK Replace the E-ECU.

86E-7 – 98E-7 Series 16-41

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

■ KDPF differential pressure sensor

 Related DTC
Failure Failure phenomenon
#B2454 KDPF Differential Pressure Sens Error (Low Volt)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B2455 KDPF Differential Pressure Sens Error (High Volt)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1454 KDPF High Pressure Side Sensor Error (Low Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1455 KDPF High Pressure Side Sens Error (High Volt)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B2453 KDPF Different Press Sens (Abnormal Learn Value)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B2452 KDPF Differential Pressure High Error
code (DTC) (Display of screen)

16-42 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Workflow
Note: For the work details, refer to “Work description” below..

ࠋ
Initial diagnosis by the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault [Check Item]:
KDPF differential pressure (high pressure) sensor output (V)
B. Failure presumption SD ” 200 (0.2 V) Open circuit of the signal wire?
by checking the 4800 (4.8 V) ” SD Open circuit of the GND wire?
detection value

Failure diagnosis operation

1. Check the E-ECU

output voltage No Replace the harness
(E-ECU + harness + sensor) or
replace the E-ECU

OK

Turn the power switch ON/OFF after

2. Check the output correcting the failure
voltage of the EGR pressure sensor No
(E-ECU + sensor + harness)
There is no current fault

OK 3. This is the same

operation as the above Normal
initial diagnosis
Replace the E-ECU

There is a
current fault

Replace the KDPF differential

pressure sensor

050233-00EN01

86E-7 – 98E-7 Series 16-43

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Wiring diagram

Sensor side coupler Wire harness side coupler

(welding surface) (welding surface)

A D B C

: Check points
050242-00EN01

Note: For the E-ECU pin layout, refer to P16-4.

 Work description
1. Check the E-ECU output voltage:
1- Connect the checker wire harness between the E-ECU and the wire harness on the equipment. Also, connect
all connectors (sensors and wire harness E-ECU).
2- Use the circuit tester to measure the voltage value between the KDPF differential pressure sensor 5 V K24 -
K77.

Voltage value Condition Corrective action

• Replace the wire harness.
K24 < 4.375 V Not OK
• Replace the E-ECU.
Check the output voltage of the KDPF differential pressure sen-
4.375 V K24 5.625 V OK (Normal range)
sor.
• Replace the wire harness.
5.625 V < K24 Not OK
• Replace the E-ECU.

Replace the wire harness or the E-ECU. Turn the power switch OFF/ON and perform the diagnosis
Not OK
using the machine monitor.
OK Refer to “Check the output voltage of the KDPF differential pressure sensor:”

16-44 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

2. Check the output voltage of the KDPF differential pressure sensor:

1- Connect the checker wire harness between the E-ECU and the wire harness on the equipment. Also, connect
all connectors (sensors and wire harness E-ECU).
2- Use the circuit tester to measure the voltage value between the sensor signals K63 - K77.

Voltage value Condition Corrective action

• Replace the wire harness.
K63 < 0.2 V Not OK
• Replace the E-ECU.
0.2 V K63 4.8 V OK (Normal range) Replace the E-ECU.
• Replace the wire harness.
4.8 V < K63 Not OK
• Replace the E-ECU.

Replace the wire harness or the E-ECU. Turn the power switch OFF/ON and perform the diagnosis
Not OK
using the machine monitor.
OK Replace the E-ECU.

3. Check the output voltage of the KDPF high pressure sensor:

1- Connect the checker wire harness between the E-ECU and the wire harness on the equipment. Also, connect
all connectors (sensors and wire harness E-ECU).
2- Use the circuit tester to measure the voltage value between the sensor signals A12 - K77.

Voltage value Condition Corrective action

• Replace the wire harness.
A12 < 0.2 V Not OK
• Replace the E-ECU.
0.2 V A12 4.8 V OK (Normal range) Replace the E-ECU.
• Replace the wire harness.
4.8 V < A12 Not OK
• Replace the E-ECU.

86E-7 – 98E-7 Series 16-45

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

■ KDPF inlet temperature sensor

 Related DTC
Failure Failure phenomenon
#B1427 KDPF Inlet Temperature Sensor Error (Low Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1428 KDPF Inlet Temperature Sensor Error (High Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1436 KDPF Inlet Temperature High Error
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault
indication condition

There is a
current fault [Check item] : KDOC inlet temperature sensor on
the Diag. Test screen
B. Presumed cause · Less than 0.2 V э GND short circuit of the sensor
after checking the signal wire?
detection value · Larger than 4.8 V э Open circuit?

Failure diagnosis

1. Check of the sensor No

resistance value Replace the sensor
(sensor unit)

OK Replace the sensor

or
2. Check of the sensor replace the
No wire harness
resistance value
(sensor + wire harness)

OK Replace the
wire harness
or
3. Check of the output No replace the E-ECU
voltage of the KDPF inlet
temperature sensor
OK Replace the ECU

044386-01EN00

16-46 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Wire diagram

E-ECU
A K81
TDPFI
KDPF inlet
temperature
sensor B K77B
A-GND

Wire harness side coupler

(welding surface)

K81 K77

: Check points
044376-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

86E-7 – 98E-7 Series 16-47

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Work description
1. Check of the sensor resistance value (sensor unit):
1- Remove the wire harness from the KDPF inlet temperature sensor.
2- Using the circuit tester, measure the resistance value between the KDPF inlet temperature sensor terminals A
and B.
3- Refer to the following diagram “KDPF inlet temperature sensor characteristics” to check that the measured
resistance value is in the normal range.
KDPF inlet temperature sensor characteristics

Relation between KDPF inlet temperature and sensor resistance value

1200
Temp. (°C) 5HVLVWDQFH>ȍ@
1140
1080 -40 170.68
1020 20 216.77
960
80 262.01
900
840 140 306.40
780 200 349.96
720
Temperature (°C)

260 392.67
660
600 320 434.54
540 380 475.57
480
440 515.76
420
360 500 555.10
300 560 593.60
240
620 631.26
180
120 680 668.08
60 740 704.05
0 800 739.18
-60
0 100 200 300 400 500 600 700 800 900 860 773.47
6HQVRUUHVLVWDQFHYDOXH ȍ 920 806.92
980 839.52
1000 850.20

044400-00EN00

Not OK Replace the KDPF inlet temperature sensor.

OK Refer to “Check of the sensor resistance value (sensor + wire-harness):”

2. Check of the sensor resistance value (sensor + wire-harness):

1- Connect the KDPF inlet temperature sensor and the wire harness and remove the E-ECU from the wire har-
ness.
2- Using the circuit tester, measure the resistance value between the E-ECU side wire harness connector termi-
nals K81 and K77B.
3- Refer to the above diagram “KDPF inlet temperature sensor characteristics” to check that the measured resis-
tance value is in the normal range.

• The coupler between the sensor and the wire harness may be defective. Replace the sensor.
Not OK
• Replace the wire harness.
OK Refer to “Check of the output voltage of the KDPF inlet temperature sensor:”

16-48 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

3. Check of the output voltage of the KDPF inlet temperature sensor:

1- Connect the checker harness between the E-ECU and the machine wire harness. Also, connect all connec-
tors (sensor and E-ECU).
2- Using the circuit tester, measure the voltage value between the KDPF inlet temperature sensor signals K81
and K77B.

Voltage value State Treatment

• Replace the wire harness.
K81 < 0.2 V Not OK
• Replace the E-ECU.
OK
0.2 V  K81  4.8 V Replace the E-ECU.
(Normal range)
• Replace the wire harness.
4.8 V < K81 Not OK
• Replace the E-ECU.

• The coupler between the wire harness and the ECU may be defective. Replace the wire harness.
Not OK
• Replace the E-ECU.
OK Replace the E-ECU.

86E-7 – 98E-7 Series 16-49

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

■ KDPF intermediate temperature sensor

 Related DTC
Failure Failure phenomenon
#B1435 KDPF Intermediate Temperature Sens Error (LowVolt)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1434 KDPF Intermediate Temperature Sens Error(HighVolt)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0420 KDPF Inter Temperature Low Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1426 KDPF InterTemperature High Error (Post-injection)
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the malfunction
current fault
indication condition

There is a
current fault [Check item] : KDOC outlet temperature sensor on
the Diag. Test screen
B. Presumed cause · Less than 0.2 V э GND short circuit of the sensor
after checking the signal wire?
detection value · Larger than 4.8 V э Open circuit?

Failure diagnosis

1. Check of the sensor No

resistance value Replace the sensor
(sensor unit)

OK Replace the sensor

or
2. Check of the sensor replace the
No
resistance value wire harness
(sensor + wire harness)

OK Replace the
wire harness
or
3. Check of the output No replace the E-ECU
voltage of the KDPF intermediate
temperature sensor
OK Replace the ECU

044387-01EN00

16-50 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Wire diagram

E-ECU
A K80
TDPFM
KDPF
intermediate
temperature
sensor
B K77C
A-GND

Wire harness side coupler

(welding surface)

K80 K77

: Check points
044376-00EN01

Note: For the E-ECU pin layout, refer to P16-4.

86E-7 – 98E-7 Series 16-51

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Work description
1. Check of the sensor resistance value (sensor unit):
1- Remove the wire harness from the KDPF intermediate temperature sensor.
2- Using the circuit tester, measure the resistance value between the KDPF intermediate temperature sensor ter-
minals A and B.
3- Refer to the following diagram “KDPF intermediate temperature sensor characteristics” to check that the mea-
sured resistance value is in the normal range.
KDPF intermediate temperature sensor characteristics

Relation between KDPF intermediate temperature and sensor resistance value

1200
Temp. (°C) 5HVLVWDQFH>ȍ@
1140
1080 -40 170.68
1020 20 216.77
960
80 262.01
900
840 140 306.40
780 200 349.96
720
Temperature (°C)

260 392.67
660
600 320 434.54
540 380 475.57
480
440 515.76
420
360 500 555.10
300 560 593.60
240
620 631.26
180
120 680 668.08
60 740 704.05
0 800 739.18
-60
0 100 200 300 400 500 600 700 800 900 860 773.47
6HQVRUUHVLVWDQFHYDOXH ȍ 920 806.92
980 839.52
1000 850.20

044400-00EN01

Not OK Replace the KDPF intermediate temperature sensor.

OK Refer to “Check of the sensor resistance value (sensor + wire harness):”

2. Check of the sensor resistance value (sensor + wire harness):

1- Connect the KDPF intermediate temperature sensor and the wire harness and remove the E-ECU from the
wire harness.
2- Using the circuit tester, measure the resistance value between the E-ECU side wire harness connector termi-
nals K80 and K77C.
3- Refer to the above diagram “KDPF intermediate temperature sensor characteristics” to check that the mea-
sured resistance value is in the normal range.

• The coupler between the sensor and the wire harness may be defective. Replace the sensor.
Not OK
• Replace the wire harness.
OK Refer to “Check of the output voltage of the KDPF intermediate temperature sensor:”

16-52 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

3. Check of the output voltage of the KDPF intermediate temperature sensor:

1- Connect the checker harness between the E-ECU and the machine wire harness. Also, connect all connec-
tors (sensor and E-ECU).
2- Using the circuit tester, measure the voltage value between the KDPF intermediate temperature sensor sig-
nals K80 and K77C.

Voltage value State Treatment

• Replace the wire harness.
K80 < 0.2 V Not OK
• Replace the E-ECU.
OK
0.2 V  K80  4.8 V Replace the E-ECU.
(Normal range)
• Replace the wire harness.
4.8 V < K80 Not OK
• Replace the E-ECU.

• The coupler between the wire harness and the ECU may be defective. Replace the wire harness.
Not OK
• Replace the E-ECU.
OK Replace the E-ECU.

86E-7 – 98E-7 Series 16-53

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

■ EGR gas temperature sensor

 Related DTC
Failure Failure phenomenon
#B041C EGR Gas Temperature Sensor Error (Low Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B041D EGR Gas Temperature Sensor Error (High Voltage)
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault
indication condition

There is a
current fault [Check item] : EGR gas temperature sensor on the
Diag. Test screen
B. Presumed cause · Less than 0.2 V э GND short circuit of the sensor
after checking the signal wire?
detection value · Larger than 4.8 V э Open circuit?

Failure diagnosis

1. Check of the sensor No

resistance value Replace the sensor
(sensor unit)

OK Replace the sensor

or
2. Check of the sensor replace the
No
resistance value wire harness
(sensor + wire harness)

Replace the
OK
wire harness
or
3. Check of the output No replace the E-ECU
voltage of the EGR gas
temperature sensor
OK Replace the ECU

044388-01EN00

16-54 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Wire diagram

Junction coupler
E-ECU
1 2
A K33
TEGR
EGR gas
temperature
sensor
B K52A
A-GND

Wire harness side coupler

(welding surface)

K33 K52A

1 2
Sensor side junction coupler E-ECU side junction coupler
(connection surface) (connection surface)

K52 K33
K33 K52

: Check points
044380-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

86E-7 – 98E-7 Series 16-55

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Work description
1. Check of the sensor resistance value (sensor unit):
1- Remove the wire harness from the EGR gas temperature sensor.
2- Using the circuit tester, measure the resistance value between the EGR gas temperature sensor terminals A
and B.
3- Refer to the following diagram “EGR gas temperature sensor characteristics” to check that the measured
resistance value is in the normal range.
EGR gas temperature sensor characteristic

Relation between EGR temperature and sensor resistance value

320
Temp. Resistance[ȍ]
300 (°C Min. Nom. Max.
280 -40 30968 32683 34388
260 -30 30647 32402 34144
-20 30117 31926 33719
240
-10 29286 31159 33019
220
0 28057 29995 31927
200 10 26319 28308 30298
7HPSHUDWXUH ƒ&

180 20 24067 26055 28069

160 25 22771 24727 26728
30 21380 23288 25253
140
40 18422 20169 21995
120 50 15421 16936 18541
100 60 12590 13838 15172
80 70 10081 11062 12120
80 7966 8708 9511
60
Nom. 90 6245 6794 7385
40
Max. 100 4881 5277 5702
20 110 3816 4098 4398
0 120 2992 3191 3401
Min. 130 2357 2496 2641
-20
140 1869 1964 2063
-40
150 1491 1555 1623
-60 160 1197 1241 1286
0 5000 10000 15000 20000 25000 30000 35000
6HQVRUUHVLVWDQFHYDOXH ȍ 170 968.7 996.9 1026.7
180 789.3 807.5 826.0
190 647.7 658.6 669.6
200 535.2 541.0 546.7
210 440.2 447.4 454.7
220 364.6 372.5 380.6
230 303.9 312.1 320.5
240 255.0 263.2 271.6
250 215.2 223.2 231.3
260 182.7 190.3 198.3
270 156.0 163.2 170.8
280 133.8 140.7 147.8
290 115.5 121.8 128.5
300 100.1 106.1 112.2
044401-00EN00

Not OK Replace the EGR gas temperature sensor.

OK Refer to “Check of the sensor resistance value (sensor + wire harness):”

16-56 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

2. Check of the sensor resistance value (sensor + wire harness):

1- Connect the EGR gas temperature sensor and the wire harness and remove the E-ECU from the wire har-
ness.
2- Using the circuit tester, measure the resistance value between the E-ECU side wire harness connector termi-
nals K33 and K52A.
3- Refer to the above diagram “EGR gas temperature sensor characteristics” to check that the measured resis-
tance value is in the normal range.

• The coupler between the sensor and the wire harness may be defective. Replace the sensor.
Not OK
• Replace the wire harness.
OK Refer to “Check of the output voltage of the EGR gas temperature sensor:”

3. Check of the output voltage of the EGR gas temperature sensor:

1- Connect the checker harness between the E-ECU and the machine wire harness. Also, connect all connec-
tors (sensor and E-ECU).
2- Using the circuit tester, measure the voltage value between the EGR gas temperature sensor signals K33 and
K52A.

Voltage value State Treatment

• Replace the wire harness.
K33 < 0.2 V Not OK
• Replace the E-ECU.
OK
0.2 V  K33  4.8 V Replace the E-ECU.
(Normal range)
• Replace the wire harness.
4.8 V < K33 Not OK
• Replace the E-ECU.

• The coupler between the wire harness and the ECU may be defective. Replace the wire harness.
Not OK
• Replace the E-ECU.
OK Replace the E-ECU.

86E-7 – 98E-7 Series 16-57

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

■ Intake manifold temperature sensor

 Related DTC
Failure Failure phenomenon
#B040C Intake Manifold Temperature Sens Error (Low Volt)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B040D Intake Manifold Temperature Sens Error (High Volt)
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault
indication condition

There is a
current fault [Check item] : Intake manifold temperature sensor on the
Diag. Test screen
B. Presumed cause · Less than 0.2 V GND short circuit of the sensor
after checking the signal wire?
detection value · Larger than 4.8 V Open circuit?

Failure diagnosis

1. Check of the sensor No

resistance value Replace the sensor
(sensor unit)

OK Replace the sensor

or
2. Check of the sensor replace the
No
resistance value wire harness
(sensor + wire harness)

Replace the
OK
wire harness
or
3. Check of the output No replace the E-ECU
voltage of the intake manifold
temperature sensor
OK Replace the ECU

044389-01EN00

16-58 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Wire diagram

Junction coupler
E-ECU
1 2
A A59
TIAIR
Intake manifold
temperature
sensor
B K52B
A-GND

Wire harness side coupler

(welding surface)

A59 K52B

1 2
Sensor side junction coupler E-ECU side junction coupler
(connection surface) (connection surface)

K52 A59
A59 K52

: Check points
044380-00EN01

Note: For the E-ECU pin layout, refer to P16-4.

86E-7 – 98E-7 Series 16-59

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Work description
1. Check of the sensor resistance value (sensor unit):
1- Remove the wire harness from the intake manifold temperature sensor.
2- Using the circuit tester, measure the resistance value between the intake manifold temperature sensor termi-
nals A and B.
3- Refer to the following diagram “Intake manifold temperature sensor characteristics” to check that the mea-
sured resistance value is in the normal range.
Intake manifold temperature sensor characteristics

Relation between intake temperature and sensor resistance value

220
Temp. Resistance[ȍ]
200 (°C Min. Nom. Max.
-40 35699 37683 39656
180 -30 34434 36412 38374
-20 32455 34400 36325
160
-10 29633 31496 33339
140 0 26009 27723 29420
10 21858 23354 24838
7HPSHUDWXUH ƒ&

120 20 17614 18847 20073

25 15595 16691 17782
100 30 13701 14664 15623
40 10386 11106 11825
80
50 7750 8273 8795
60 60 5742 6116 6488
70 4252 4516 4780
40 80 3162 3347 3534
Nom. 90 2366 2499 2631
20
100 1787 1881 1975
Max.
0 110 1362 1431 1498
120 1050 1098 1148
-20 130 816.2 852.3 888.3
Min. 140 641.2 667.8 694.6
-40
150 508.9 528.5 548.1
-60 160 405.3 422.1 438.9
0 5000 10000 15000 20000 25000 30000 35000 40000 170 325.9 340.2 354.4
6HQVRUUHVLVWDQFHYDOXH ȍ 180 264.4 276.5 288.7
190 216.2 226.6 236.9
200 178.2 187.1 196.1
044402-00EN00

Not OK Replace the intake manifold temperature sensor.

OK Refer to “Check of the sensor resistance value (sensor + wire harness):”

16-60 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

2. Check of the sensor resistance value (sensor + wire harness):

1- Connect the intake manifold temperature sensor and the wire harness and remove the E-ECU from the wire
harness.
2- Using the circuit tester, measure the resistance value between the E-ECU side wire harness connector termi-
nals A59 and K52B.
3- Refer to the above diagram “Intake manifold temperature sensor characteristics” to check that the measured
resistance value is in the normal range.

• The coupler between the sensor and the wire harness may be defective. Replace the sensor.
Not OK
• Replace the wire harness.
OK Refer to “Check of the output voltage of the intake manifold temperature sensor:”

3. Check of the output voltage of the intake manifold temperature sensor:

1- Connect the checker harness between the E-ECU and the machine wire harness. Also, connect all connec-
tors (sensor and E-ECU).
2- Using the circuit tester, measure the voltage value between the intake manifold temperature sensor signals
A59 and K52B.

Voltage value State Treatment

• Replace the wire harness.
A59 < 0.2 V Not OK
• Replace the E-ECU.
OK
0.2 V  A59  4.8 V Replace the E-ECU.
(Normal range)
• Replace the wire harness.
4.8 V < A59 Not OK
• Replace the E-ECU.

• The coupler between the wire harness and the ECU may be defective. Replace the wire harness.
Not OK
• Replace the E-ECU.
OK Replace the E-ECU.

86E-7 – 98E-7 Series 16-61

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

■ Exhaust manifold temperature sensor

 Related DTC
Failure Failure phenomenon
#B0545 Exhaust Manifold Temperature Sens Error (Low Volt)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0546 Exhaust Manifold Temperature Sens Error (HighVolt)
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault
indication condition

There is a
current fault [Check item] : Exhaust manifold temperature sensor on
the Diag. Test screen
B. Presumed cause · Less than 0.2 V GND short circuit of the sensor
after checking the signal wire?
detection value · Larger than 4.8 V Open circuit?

Failure diagnosis

1. Check of the sensor No

resistance value Replace the sensor
(sensor unit)

OK Replace the sensor

or
2. Check of the sensor replace the
No
resistance value wire harness
(sensor + wire harness)

Replace the
OK
wire harness
or
3. Check of the output No replace the E-ECU
voltage of the exhaust manifold
temperature sensor
OK Replace the ECU

044390-01EN00

16-62 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Wire diagram

Junction coupler
E-ECU
1 2
A K56
TEXMH
Exhaust manifold
temperature
sensor
B A51A
A-GND

Wire harness side coupler

(welding surface)

K56 A51A

1 2
Sensor side junction coupler E-ECU side junction coupler
(connection surface) (connection surface)

K56 A51
A51 K56

: Check points
044381-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

86E-7 – 98E-7 Series 16-63

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Sensor related

 Work description
1. Check of the sensor resistance value (sensor unit):
1- Remove the wire harness from the exhaust manifold temperature sensor.
2- Using the circuit tester, measure the resistance value between the exhaust manifold temperature sensor ter-
minals A and B.
3- Refer to the following diagram “exhaust manifold temperature sensor characteristics” to check that the mea-
sured resistance value is in the normal range.
Exhaust manifold temperature sensor characteristics

Relation between exhaust gas temperature and sensor resistance value

700
7HPS ƒ& 5HVLVWDQFH>ȍ@
10 209.15

600 650 649.77

500

400
7HPSHUDWXUH ƒ&

300

200

100

0
0 100 200 300 400 500 600 700

6HQVRUUHVLVWDQFHYDOXH ȍ
044404-00EN00

Not OK Replace the exhaust manifold temperature sensor.

OK Refer to “Check of the sensor resistance value (sensor + wire harness):”

16-64 86E-7 – 98E-7 Series

Sensor related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

2. Check of the sensor resistance value (sensor + wire harness):

1- Connect the exhaust manifold temperature sensor and the wire harness and remove the E-ECU from the wire
harness.
2- Using the circuit tester, measure the resistance value between the E-ECU side wire harness connector termi-
nals K56 and A51A.
3- Refer to the above diagram “exhaust manifold temperature sensor characteristics” to check that the measured
resistance value is in the normal range.

• The coupler between the sensor and the wire harness may be defective. Replace the sensor.
Not OK
• Replace the wire harness.
OK Refer to “Check of the output voltage of the exhaust manifold temperature sensor:”

3. Check of the output voltage of the exhaust manifold temperature sensor:

1- Connect the checker harness between the E-ECU and the machine wire harness. Also, connect all connec-
tors (sensor and E-ECU).
2- Using the circuit tester, measure the voltage value between the exhaust manifold temperature sensor signals
K56 and A51A.

Voltage value State Treatment

• Replace the wire harness.
K56 < 0.2 V Not OK
• Replace the E-ECU.
OK
0.2 V  K56  4.8 V Replace the E-ECU.
(Normal range)
• Replace the wire harness.
4.8 V < K56 Not OK
• Replace the E-ECU.

• The coupler between the wire harness and the ECU may be defective. Replace the wire harness.
Not OK
• Replace the E-ECU.
OK Replace the E-ECU.

86E-7 – 98E-7 Series 16-65

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Contact output related

Contact output related

■ Main relay
 Related DTC
Failure Failure phenomenon
#B068B Main Relay Contact Stuck
code (DTC) (Display of screen)

Failure Failure phenomenon

#B068A Main Relay Early Opening
code (DTC) (Display of screen)

16-66 86E-7 – 98E-7 Series

Contact output related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Workflow
Note: For the details of work, refer to the following “Work description”. For the operation method of the SMARTAS-
SIST-DIRECT, refer to the separate “SMARTASSIST-DIRECT operation manual”.
Initial diagnosis with the machine monitor

There is a DTC in the fault

A. Check of the history indication Check of the malfunction condition
current fault ‡Is the battery terminal loose?
indication ‡Is the battery switch turned off
within 30 seconds after turning
off the key switch?
No finding

Key off (standby for 30 seconds or more)

[Check Item] Login to the SMARTASSIST-DIRECT

B. Login to the ‡Login failed: The main relay is not stuck
SMARTASSIST-DIRECT ‡Login successful: The ECU internal main relay fault
Replace the ECU

Failure diagnosis work

1. Check the battery terminal Yes

Retighten the battery terminal
for looseness

Replace the battery switch

No
2. Inspect the battery switch Direct the battery switch operation method
(do not operate the switch for 30 seconds
after key off)

3. Login is possible Possible

30 seconds after turning off Replace the ECU
the key switch

4. Visually check the ECU There is abnormality

Replace the ECU
connector

Insufficient capacity
5. The battery condition Replace or charge the battery
Insufficient charging

6. Does the condition recur Yes

Return to 1 and re-check
by repeating key on/off?

No problem
050498-00EN00

86E-7 – 98E-7 Series 16-67

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Contact output related

 Wire diagram
Note: The main relay is equipped with an ECU.

Battery switch ECU

(check the driven machine)
K01
VB
K03
VB
K05
VB

B K88
IGNSW
BR
C K02
GND
K04
Power switch GND
K06
GND
Battery

050499-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

16-68 86E-7 – 98E-7 Series

Contact output related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Check the battery terminal for looseness
• Check whether or not the wiring from the battery to the ECU VB terminal is loose or damaged.
• Check whether or not the joints to the battery GND terminal and the frame are loose.
• Check whether or not the wiring from the ECU GND terminal to the frame GND is loose or damaged.
• Check whether or not the wiring from the ECU IGN terminal to the key switch is loose or damaged.

2. Inspect the battery switch

Depending on the driven machine, there is a battery switch for the purpose of long-term storage besides the key
switch. For details, contact Komatsu dealer.
• Check the wiring of the battery switch for looseness.
• Check the battery switch for abnormality.
• Do not perform the cutoff operation of the battery switch after the key off until the system operating lamp goes
off. Direct the operation method to the operator.

3. Login check to the SMARTASSIST-DIRECT

When 30 seconds or more are elapsed after turning off the key switch, the ECU operation stops completely. Con-
nect the SMARTASSIST-DIRECT after the elapse of 30 seconds or more after the key off and check whether or
not you can login. If you can login after the elapse of 30 seconds or more, there is a possibility that the ECU inter-
nal main relay is faulty. Replace the E-ECU.

4. Visually check the ECU connector

Visually check the VB pins (K01, K03, K05) and the GND pins (K02, K04, K06) of the ECU connector. If there is
broken or bent pin, replace the ECU.

5. The battery condition

The insufficient battery charging or the battery capacity reduction may lead to the supply voltage reduction, result-
ing in the early opening abnormality of the main relay. Inspect the battery.

6. Check the recurrence

Repeat turning on/off the key switch for a few times and check that the concerned abnormality does not recur. If
the abnormality recurs, perform the inspection again from Step 1. If the abnormality does not recur, there is no
problem with the main relay.

86E-7 – 98E-7 Series 16-69

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Contact output related

■ Startup assist relay (Glow relay)

 Related DTC
Failure Failure phenomenon
#B0543 Startup Assist Relay Open Circuit
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0541 Startup Assist Relay GND Short Circuit
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”. For the operation method of the SMARTAS-
SIST-DIRECT, refer to the separate “SMARTASSIST-DIRECT operation manual”.

Initial diagnosis with the machine monitor

There is a DTC in the fault

A. Check of the history indication
current fault Check of the malfunction condition
indication

There is a current fault

[Check Item] Startup assist relay
B. Presumed cause after Check the relay operation by the forced drive operation
checking the detection value ‡Relay on/off possible: Normal
‡Relay on/off not possible: Check the failure diagnosis
in the following:

Failure diagnosis work

1. Check the relay coil No

resistance value (relay unit) Replace the relay

2. Check the relay No 3. Wire harness NG

coil resistance value (relay + Replace the
conduction check wire harness
wire harness side)

OK
OK

Replace the ECU

4. Relay operation check No or
(using the SMARTASSIST wire harness
-DIRECT)

OK
Replace the ECU

050500-00EN00

16-70 86E-7 – 98E-7 Series

Contact output related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Wire diagram

Battery

Startup assist relay

Starter

Fuse
S
80 A
D C

E-ECU
K70
SAID-RLY

Glow plug

Wire harness side coupler

(welding surface)

B62

B00 K70

B50
: Check points
050501-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

86E-7 – 98E-7 Series 16-71

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Contact output related

 Work description
1. Check the relay coil resistance value (relay unit)
1- Remove the wire harness from the startup assist relay.
2- Use the circuit tester to measure the resistance value between the relay side terminals C - D.
Reference: Total resistance value of the standard startup assist relay

Relay Terminal Specification

YM129927-77930 (40 A) Relay coil side C - D 103 Ω ± 10 % (at 20 °C)
YM129927-77920 (70 A) Relay coil side C - D 103 Ω ± 10 % (at 20 °C)
YM129927-77900 (90 A) Relay coil side C - D 80 Ω (at 20 °C)

Not OK Replace the startup assist relay.

Check the relay coil resistance value while the startup assist relay and the wire harness are connected.
OK
Refer to “Check the relay coil resistance value (relay + wire harness side)”

2. Check the relay coil resistance value (relay + wire harness side)
1- Connect the startup assist relay to the wire harness. Remove the E-ECU from the wire harness.
2- Use the circuit tester to measure the resistance value between the ECU connectors K70 - K02.
Note: Refer to the above-mentioned reference “Total resistance value of the standard startup assist relay”.

Not OK Check the wire-harness conduction. Refer to “Wire harness conduction check”.
Use the SMARTASSIST-DIRECT to check the operation of the startup assist relay.
OK
Refer to “Relay operation check”.

3. Wire harness conduction check

1- Remove the wire harness from the startup assist relay and the E-ECU.
2- Use the circuit tester to measure the wire harness conduction.

Terminal Conduction Condition

Yes OK: Normal
Relay coil K70 side (between ECU and relay connector)
No Not OK: Wire harness open circuit
Yes OK: Normal
Relay coil B00 side (between ECU and relay connector)
No Not OK: Wire harness open circuit
No OK: Normal
Between K70 - GND/K02/K04/K06
Yes Not OK: Wire harness open circuit
No OK: Normal
Between K70 - VB/K01/K03/K05
Yes Not OK: Wire harness open circuit

• Check the wire harness for damage. Check the wiring for mis-connection.
Not OK
• Replace the wire harness.
Use the SMARTASSIST-DIRECT to check the operation of the startup assist relay.
OK
Refer to “Relay operation check”.

16-72 86E-7 – 98E-7 Series

Contact output related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

4. Relay operation check

1- Connect the checker harness between the ECU and the machine wire harness (For details, refer to “How to
use the Tier 4 checker harness” on P16-6). Also, connect all connectors (startup assist relay, ECU).
2- Turn on the key switch. Login to the SMARTASSIST-DIRECT.
3- Operate the startup assist relay on the “Diagnosis Test: Forced Drive” of the SMARTASSIST-DIRECT. At this
time, measure the voltage between the terminals K70 - K02.

ON/OFF setting condition Voltage value Voltage value

2.5 V or more OK: Normal
ON
Less than 2.5 V Not OK: Wire harness GND short circuit or ECU failure
1.75 V or below OK: Normal
OFF
Over 1.75 V Not OK: Wire harness power short circuit or ECU failure

• Check the wire harness for damage. Check the wiring for mis-connection.
Not OK
• Replace the wire harness.
OK Replace the E-ECU.

86E-7 – 98E-7 Series 16-73

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Contact input related

Contact input related

■ Contact input related 1

 Related DTC
Failure Failure phenomenon
#B1192 Oil Pressure Switch Open Circuit
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1198 Oil Pressure Low Error Alarm
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1562 Charge Switch Open Circuit
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1568 Charge Alarm
code (DTC) (Display of screen)

16-74 86E-7 – 98E-7 Series

Contact input related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Workflow
Note: For the details of work, refer to the following “Work description”. For the operation method of the SMARTAS-
SIST-DIRECT, refer to the separate “SMARTASSIST-DIRECT operation manual”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault
indication condition

There is a [Check item] : Oil pressure switch and charge switch

current fault on the Diag. Test screen
* On the SA-D screen, 0 is open and 1 is closed.
B. Presumed cause · Before the engine start : ON Normal
after checking the OFF Fault?
detection value · After the engine start : ON Fault?
OFF Normal

Failure diagnosis

1. Check of the conduction No Replace each contact

(contact input switch unit) input switch

OK Replace the
wire harness or
replace each contact
2. Check of the conduction No
(contact input switch input switch
+ wire harness)

Replace the
OK
wire harness
or
No replace the E-ECU
3. Contact input switch
operation check

OK Replace the E-ECU

044391-01EN00

86E-7 – 98E-7 Series 16-75

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Contact input related

 Wire diagram

Battery

Power switch
E-ECU
B
BR
C

A50
UB3

Lamp Lamp Lamp Lamp

Oil/ water
separator
K40
WSSW

K41
ACLSW

Air cleaner
K66
CHGSW

K15
LOPSW

Charge Oil pressure

switch switch

: Check points
044382-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

16-76 86E-7 – 98E-7 Series

Contact input related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Check of the conduction (contact input switch unit):
1- Turn off the ECU power.
2- Remove the wire harness from each contact input switch.
3- Using the circuit tester and seeing the below table, check the conduction between the contact input terminal
and the body frame.

Conduction (Between the terminal

Item Terminal No. State
and the body frame)
Yes OK: Normal
Oil pressure switch K15
No Not OK: Abnormal
No OK: Normal
Charge switch K66
Yes Not OK: Abnormal

Not OK Replace the contact input switch.

OK Refer to “Check of the conduction (contact input switch + wire harness):”

2. Check of the conduction (contact input switch + wire harness):

1- Connect the contact input switch and the wire harness and remove the E-ECU from the wire harness.
2- Using the circuit tester, measure the conduction between the E-ECU connector terminal and the body frame
of the wire harness. For the number of the terminal that is checked, refer to 1. above.

• The coupler between the contact input switch and the wire harness may be defective. Replace the
Not OK contact input switch.
• Replace the wire harness.
OK Refer to “Contact input switch operation check:”

3. Contact input switch operation check:

1- Connect all connectors (contact input switch, E-ECU, junction coupler).
2- Connect the SMARTASSIST-DIRECT and login to the SMARTASSIST-DIRECT after turning on the power switch.
3- Monitor each item on the SMARTASSIST-DIRECT : “Digital input, etc. Diag. Test” and check the ON/OFF dis-
play of the contact input switch in the specified condition.

Item Check condition ON/OFF indication State

ON (1) OK: Normal
Before engine start
OFF (0) Not OK: Abnormal
Oil pressure switch
OFF (0) OK: Normal
During engine operation
ON (1) Not OK: Abnormal
ON (1) OK: Normal
Before engine start
OFF (0) Not OK: Abnormal
Charge switch
OFF (0) OK: Normal
During engine operation
ON (1) Not OK: Abnormal

• The coupler between the wire harness and the ECU may be defective. Replace the wire harness.
Not OK
• Replace the E-ECU.
OK Replace the E-ECU.

86E-7 – 98E-7 Series 16-77

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Contact input related

■ Contact input related 2

 Related DTC
Failure Failure phenomenon
#B1101 —
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1151 —
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following “Work description”. For the operation method of the SMARTAS-
SIST-DIRECT, refer to the separate “SMARTASSIST-DIRECT operation manual”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault
indication condition

There is a [Check item] : Air cleaner switch and oil/water

current fault separator switch on the Diag. Test screen
*On the SA-D screen, 0 is open and 1 is closed.
B. Presumed cause “Air cleaner sensor” and “oil/water separator
after checking the alarm switch”
detection value : OFF Normal
: ON Abnormal?

Failure diagnosis

1. Check of the conduction No Replace each contact

(contact input switch unit) input switch

OK Replace the
wire harness or
replace each contact
2. Check of the conduction No
(contact input switch input switch
+ wire harness)

OK Replace the E-ECU

or
replace wire harness
3. Contact input switch No
operation check

OK Replace the E-ECU

044392-01EN00

16-78 86E-7 – 98E-7 Series

Contact input related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Wire diagram

Battery

Power switch
E-ECU
B
BR
C

A50
UB3

Lamp Lamp Lamp Lamp

Oil/ water
separator
K40
WSSW

K41
ACLSW

Air cleaner

K66
CHGSW

K15
LOPSW

Charge Oil pressure

switch switch

: Check points
044382-00EN01

Note: For the E-ECU pin layout, refer to P16-4.

86E-7 – 98E-7 Series 16-79

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Contact input related

 Work description
1. Check of the conduction (contact input switch unit):
1- Turn off the ECU power.
2- Remove the wire harness from each contact input switch.
3- Using the circuit tester and seeing the below table, check the conduction between the contact input terminals
of each switch.

Conduction (Between each switch

Item Terminal No. State
terminal)
No OK: Normal
Air cleaner switch K41
Yes Not OK: Abnormal
No OK: Normal
Oil/water separator switch K40
Yes Not OK: Abnormal

Not OK Replace the contact input switch.

OK Refer to “Check of the conduction (contact input switch + wire harness):”

2. Check of the conduction (contact input switch + wire harness):

1- Connect the contact input switch and the wire harness and remove the E-ECU and key switch terminal (BR)
from the wire harness.
2- Using the circuit tester, check the conduction between the E-ECU connector terminal and the key switch ter-
minal (BR) of the wire harness. For the number of the terminal that is checked, refer to 1. above.

• The coupler between the contact input switch and the wire harness may be defective. Replace the
Not OK contact input switch.
• Replace the wire harness.
OK Refer to “Contact input switch operation check:”

3. Contact input switch operation check:

1- Connect all connectors (contact input switch, E-ECU, key switch terminal (BR)).
2- Connect the SMARTASSIST-DIRECT : and login to the SMARTASSIST-DIRECT after turning on the power
switch.
3- Monitor each item on the SMARTASSIST-DIRECT : “Diag. Test” and check the ON/OFF display of the contact
input switch in the specified condition.

Item ON/OFF indication State

OFF (0) OK: Normal
Air cleaner switch
ON (1) Not OK: Abnormal
OFF (0) OK: Normal
Oil/water separator switch
ON (1) Not OK: Abnormal

• The coupler between the wire harness and the E-ECU may be defective. Replace the wire harness.
Not OK
• Replace the E-ECU.
OK Replace the E-ECU.

16-80 86E-7 – 98E-7 Series

CRS (common rail system) related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

CRS (common rail system) related

■ Injector

Injector open circuit and coil short circuit

 Related DTC
#B0204
Injector of 4th Cylinder OpenC (Inherent Location)
Failure (4-cylinder engine) Failure phenomenon
code (DTC) #B0203 (Display of screen)
—
(3-cylinder engine)

Failure Failure phenomenon

#B0202 Injector of 2nd Cylinder OpenC (Inherent Location)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0201 Injector of 1st Cylinder OpenC (Inherent Location)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0203 —
code (DTC) (Display of screen)

#B0271
Injector of 4th Cylinder Coil Short Circuit
Failure (4-cylinder engine) Failure phenomenon
code (DTC) #B0268 (Display of screen)
—
(3-cylinder engine)

Failure Failure phenomenon

#B0265 Injector of 2nd Cylinder Coil Short Circuit
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0262 Injector of 1st Cylinder Coil Short Circuit
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0268 Injector of 3rd Cylinder Coil Short Circuit
code (DTC) (Display of screen)

86E-7 – 98E-7 Series 16-81

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS CRS (common rail system) relat-

 Workflow
Note: For the details of work, refer to the following “Work description”.

ࠋ
Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication
There is a
current fault

Current fault is occurring

Failure diagnosis

1. Check of the injector resistance No Replace the injector

value (Injector)

OK

2. Check of the injector resistance No Replace the injector

value (injector + wire harness) or wire harness*

OK
*In case of the injector open circuit and coil short circuit error
detection, if No in the operation 2, there may be a fault in the
Replace the wire harness or wire harness, but in case of the injector short circuit error, the
E-ECU wire harness is normal, so do not replace it.

044393-01EN00

16-82 86E-7 – 98E-7 Series

CRS (common rail system) related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Wire diagram

Junction coupler E-ECU

Injector 1 2
A A47
INJ1-2H
#1
B A17
INJ1-2L

C A33
INJ1-1H
#4
D A16
INJ1-1H

E A32
INJ2-2H
#3 F A02
INJ2-2L

G A31
INJ2-1H
#2 H A01
INJ2-1L

Wire harness side coupler

(welding surface)

1st cylinder 4th cylinder 3rd cylinder 2nd cylinder

A47 A17 A33 A16 A32 A02 A31 A01

Sensor side junction coupler E-ECU side junction coupler

1 2
(connection surface) (connection surface)

A33 A16 A47 A17 A31 A01 A01 A31 A17 A47 A16 A33

A32 A02 A02 A32

: Check points
044394-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

86E-7 – 98E-7 Series 16-83

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS CRS (common rail system) relat-

 Work description
1. Check of the injector resistance value (injector unit):
1- Remove the wire harness from the injector.
2- Using the circuit tester, measure the resistance value (total resistance) between the injector terminals A and
B, E and F, and G and H.
Reference: Total resistance of the injector

Terminal Specification
Between the injector terminals 255 ± 40 mΩ

Not OK Replace the injector

OK Refer to “Check of the injector resistance value (injector + wire harness):”

2. Check of the injector resistance value (injector + wire harness):

 Junction coupler is not connected
1- Connect the injector and the wire harness and remove the E-ECU from the wire harness. Here, refer to the
above wire diagram and remove the wire harness of the junction coupler (2) side from the wire harness of the
junction coupler (1) side.
2- Using the circuit tester, measure the resistance value (total resistance) between A47 and A17, A33 and A16.
A32 and A02, and A31 and A01 of the junction coupler (1) side wire harness.
Note: Refer to the above-mentioned reference “Total resistance of the injector”.

• The coupler between the injector and the wire harness may be defective. Replace the injector.
Not OK
• Replace the wire harness.
OK Refer to “Junction coupler is connected”

 Junction coupler is connected

1- Connect the injector and the wire harness and remove the E-ECU from the wire harness. Here, refer to the
above wire diagram and remove the wire harness of the junction coupler (2) side to the wire harness of the
junction coupler (1) side.
2- Using the circuit tester, measure the resistance value (total resistance) between A47 and A17, A33 and A16.
A32 and A02, and A31 and A01 of the E-ECU side wire harness.
Note: Refer to the above-mentioned reference “Total resistance of the injector”.

Not OK The junction coupler may be defective. Replace the wire harness.
• The coupler between the wire harness and the E-ECU may be defective. Replace the wire harness.
OK
• Replace the E-ECU.

16-84 86E-7 – 98E-7 Series

CRS (common rail system) related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

Injector short circuit

 Related DTC
Failure #B1271
Injector of 4th Cylinder Short Circuit
code (DTC) (4-cylinder engine) Failure phenomenon
#B1268 (Display of screen)
SPN/FMI —
(3-cylinder engine)

Failure Failure phenomenon

#B1265 Injector of 2nd Cylinder Short Circuit
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1262 Injector of 1st Cylinder Short Circuit
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1268 Injector of 3rd Cylinder Short Circuit
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1146 Injector Drive Circuit (Bank1) Short Circuit
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1149 Injector Drive Circuit (Bank2) Short Circuit
code (DTC) (Display of screen)

 Workflow
Refer to “Injector open circuit and coil short circuit”

 Wire diagram
Refer to “Injector open circuit and coil short circuit”

86E-7 – 98E-7 Series 16-85

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS CRS (common rail system) relat-

 Work description
1. Check of the injector resistance value (injector unit):
1- Remove the wire harness from the injector.
2- Using the circuit tester, measure the resistance value (total resistance) between the injector terminals A and
B, C and D, E and F, and G and H.
Reference: Total resistance of the injector

Terminal Specification
Between the injector terminals 255 ± 40 mΩ

Not OK Replace the injector

OK Refer to “Check of the injector resistance value (injector + wire harness):”

2. Check of the injector resistance value (injector + wire harness):

 Junction coupler is not connected
1- Connect the injector and the wire harness and remove the E-ECU from the wire harness. Here, refer to the
above wire diagram and remove the wire harness of the junction coupler (2) side from the wire harness of the
junction coupler (1) side.
2- Using the circuit tester, measure the resistance value (total resistance) between A47 and A17, A33 and A16.
A32 and A02, and A31 and A01 of the junction coupler (1) side wire harness.
Note: Refer to the above-mentioned reference “Total resistance of the injector”.

Not OK Replace the wire harness.

OK Refer to “Junction coupler is connected”

 Junction coupler is connected

1- Connect the injector and the wire harness and remove the E-ECU from the wire harness. Here, refer to the
above wire diagram and remove the wire harness of the junction coupler (2) side to the wire harness of the
junction coupler (1) side.
2- Using the circuit tester, measure the resistance value (total resistance) between A47 and A17, A33 and A16.
A32 and A02, and A31 and A01 of the E-ECU side wire harness.
Note: Refer to the above-mentioned reference “Total resistance of the injector”.

Not OK Replace the wire harness.

• The coupler between the wire harness and the E-ECU may be defective. Replace the wire harness.
OK
• Replace the E-ECU.

16-86 86E-7 – 98E-7 Series

CRS (common rail system) related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

■ High-pressure pump (MPROP)

 Related DTC
Failure Failure phenomenon
#B1641 SCV(MPROP) (Low Side VB Short)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1643 SCV(MPROP) (Low Side GND Short)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0629 SCV(MPROP) (High Side VB Short)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1642 SCV(MPROP) (High Side GND Short)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0627 SCV(MPROP) (Open Circuit)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1645 SCV(MPROP) (Pump Overload Error)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B062A SCV(MPROP) (Drive Current High Error)
code (DTC) (Display of screen)

86E-7 – 98E-7 Series 16-87

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS CRS (common rail system) relat-

 Workflow
Note: For the work details, refer to “Work description” below.

ࠋ
Initial diagnosis by the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault

Currently trouble is occurring

Failure diagnosis operation

1. Check the SCV No

(MPROP) resistance value Replace the SCV (MPROP)
(SCV (MPROP) unit)

OK

2. Check the SCV Replace the SCV (MPROP)

(MPROP) resistance value No
or
(SCV (MPROP) + wire harness
wire harness)
OK

Replace the wire harness or

E-ECU

050503-00EN00

16-88 86E-7 – 98E-7 Series

CRS (common rail system) related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Wiring diagram

E-ECU
A A04
MPROP-H

SCV
(MPROP)
B A05
HPPSOL

Wire harness side coupler

(welding surface)

A04 A05

: Check points

050504-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

 Work description
1. Check of the SCV (MPROP) resistance value (SCV (MPROP) unit):
1- Remove the wire harness from the SCV (MPROP).
2- Using the circuit tester, measure the resistance value (total resistance) between the SCV (MPROP) terminals
A and B.
Reference: Total resistance of the SCV (MPROP)

Terminal Specification
Between the SCV (MPROP) terminals 2.60 - 3.15 Ω

Not OK Replace the SCV (MPROP).

OK Refer to “Check of the SCV (MPROP) resistance value (SCV (MPROP) + wire harness):”

2. Check of the SCV (MPROP) resistance value (SCV (MPROP) + wire harness):
1- Connect the SCV (MPROP) and the wire harness and remove the E-ECU from the wire harness.
2- Using the circuit tester, measure the resistance value (total resistance) between A04 and A05 of the E-ECU
side wire harness.
Note: Refer to the above-mentioned reference “Total resistance of the SCV (MPROP)”.

Not OK The wire harness may be defective. Replace the wire harness.
OK Replace the E-ECU.

86E-7 – 98E-7 Series 16-89

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Actuator

Actuator

■ Intake throttle drive circuit

 Related DTC
Failure Failure phenomenon
#B0660 No-load of Throttle Valve Drive H Bridge Circuit
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1660 O-load on the Drive H Bridge Cir of Throttle Valve
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1658 Power Short of Throttle Valve Drive H Bridge Out 1
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1661 VB P Short of Throttle Valve Drive H Bridge Out 2
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1659 GND Short of Throttle Valve Drive H Bridge Out 1
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1662 GND Short of Throttle Valve Drive H Bridge Out 2
code (DTC) (Display of screen)

16-90 86E-7 – 98E-7 Series

Actuator METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Workflow
Note: For the work details, refer to “Work description” below.

ࠋ
Initial diagnosis by the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault

Currently trouble is occurring

Failure diagnosis operation

1. Check the motor No

resistance value Replace the motor
(motor unit)

OK

2. Check the motor Replace the motor

No or
resistance value
(motor + harness) replace the harness

OK

3. Check the wire No Replace the harness

harness conduction
(harness)
OK
Replace the harness
or
replace the E-ECU

045710-00EN00

86E-7 – 98E-7 Series 16-91

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Actuator

 Wiring diagram

A-B
Wire harness side coupler
(welding surface)

Sealing
A20 A19 K52 K23 K20
plug

Junction coupler
E-ECU
1 2
motor A A19
IVDCM-H

M
B A20
IVDCM-L

Sensor side junction coupler E-ECU side junction coupler

1 2
(connection surface) (connection surface)

A19 A20 A20 A19

: Check points
045711-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

16-92 86E-7 – 98E-7 Series

Actuator METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Check of the motor resistance value (motor unit):
1- Remove the motor from the wire harness.
2- Use the circuit tester to measure the resistance value (total resistance value) between the motor terminals A
and B.
Reference: Total resistance of the motor

Terminal Specification
Between terminal A and B 0.3 - 100 z (20°C)

Not OK Replace the motor.

OK Refer to “Check of the motor resistance value (motor + wire harness):”

2. Check of the motor resistance value (motor + wire harness):

1- Connect the motor and the wire harness. Remove the E-ECU from the harness.
2- Use the circuit tester to measure the resistance value (total resistance value) between the E-ECU side wire
harness connectors A19 and A20.
Note: Refer to the above-mentioned reference “Total resistance of the motor”.

• A coupler failure between the motor and the wire harness may be caused. Replace the motor.
No
• Replace the wire harness.
Applied Refer to “Check the wire harness conduction:”

3. Check the wire harness conduction:

1- Remove the wire harness from the motor and the E-ECU. Here, keep the junction coupler connected.
2- Perform the wire harness conduction check between the terminal 1 and the terminal 2 in the below table while
referring to P16-4 "E-ECU pin layout diagram".

Detection error Check method

No-load of throttle valve drive H bridge circuit Perform the check pattern 1
Power short circuit of throttle valve drive H bridge output 1 Perform the check pattern 2
Power short circuit of throttle valve drive H bridge output 2 Perform the check pattern 3
GND short circuit of throttle valve drive H bridge output 1 Perform the check pattern 4
GND short circuit of throttle valve drive H bridge output 2 Perform the check pattern 5

86E-7 – 98E-7 Series 16-93

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Actuator

Reference: Intake throttle drive circuit conduction check pattern 1

Terminal 2 (DC motor

Terminal 1 (E-ECU side
side wire harness con- Conduction Condition
wire harness connector)
nector)
Yes OK: Normal
A19 Motor terminal A
No Not OK: Abnormal
Yes OK: Normal
A20 Motor terminal B
No Not OK: Abnormal

Reference: Intake throttle drive circuit conduction check pattern 2

Terminal 1 (E-ECU side Terminal 2 (E-ECU side

Conduction Condition
wire harness connector) wire harness connector)
Yes Not OK: Abnormal
A19 VB terminal
No OK: Normal

Reference: Intake throttle drive circuit conduction check pattern 3

Terminal 1 (E-ECU side Terminal 2 (E-ECU side

Conduction Condition
wire harness connector) wire harness connector)
Yes Not OK: Abnormal
A20 VB terminal
No OK: Normal

Reference: Intake throttle drive circuit conduction check pattern 4

Terminal 1 (E-ECU side Terminal 2 (E-ECU side

Conduction Condition
wire harness connector) wire harness connector)
Yes Not OK: Abnormal
A19 GND terminal
No OK: Normal

Reference: Intake throttle drive circuit conduction check pattern 5

Terminal 1 (E-ECU side Terminal 2 (E-ECU side

Conduction Condition
wire harness connector) wire harness connector)
Yes Not OK: Abnormal
A20 GND terminal
No OK: Normal

Not OK Interrupted or short circuited between the wire harnesses. Replace the wire harness.
• A coupler failure between the E-ECU and the wire harness may be caused. Replace the wire har-
OK ness.
• Replace the E-ECU.

16-94 86E-7 – 98E-7 Series

Actuator METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

■ EGR valve
 Related DTC
Failure Failure phenomenon
#B0404 EGR Voltage High Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1404 EGR Voltage Low Error
code (DTC) (Display of screen)

 Workflow
Note: For the work details, refer to “Work description” below.

ࠋ
Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault

Currently trouble is occurring

Failure diagnosis operation

Charge the battery

1. Check the No
battery voltage or
replace the battery

OK

2. Check the output OK

voltage to the EGR valve Replace the EGR valve
(E-ECU + harness)

No

3. Check the wire No Replace the harness

harness conduction
(harness)
OK
Replace the harness
or
replace the E-ECU

045809-00EN00

86E-7 – 98E-7 Series 16-95

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Actuator

 Wiring diagram

A-D Wire harness side coupler

(welding surface)

B42 B00B K76 K54

O B L P

C D B A

EGR Junction coupler E-ECU

1 2
A K54
CAN1H

B K76
CAN1L
C K01
VB
Main relay K03
VB
K05
VB

Battery (+)

D Battery (-) K02

GND
K04
GND
K06
GND

Sensor side junction coupler E-ECU side junction coupler

1 (connection surface)
2 (connection surface)

B42 K54 K76 B00B B00B K76 K54 B42

: Check points
045810-00EN02

Note: For the E-ECU pin layout, refer to P16-4.

16-96 86E-7 – 98E-7 Series

Actuator METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Check the battery voltage:
Turn on the power switch and check the battery voltage.
1- Check whether or not the battery voltage is reduced due to the battery life.
2- Check whether or not the battery output is too high.
Reference: Battery voltage check pattern 1

Terminal 1 (battery) Terminal 2 (battery) Voltage value Condition

8 V or below Not OK: Abnormal
Battery (+) Battery (-) 8 V - 16 V OK: Normal
16 V or above Not OK: Abnormal

Not OK Charge or replace the battery.

OK Check the actions of the other E-ECU.

2. Check the output voltage to the EGR valve:

1- Remove the EGR valve from the wire harness.
2- Turn on the power switch and check the battery voltage. Refer to the wire diagram and measure the wire har-
ness between C and D.
Reference: Battery voltage check pattern 2

Terminal 1 (EGR valve Terminal 2 (EGR valve

side wire harness con- side wire harness con- Voltage value Condition
nector) nector)
8 V or below Not OK: Abnormal
C (B42) D (B00B) 8 V - 18 V OK: Normal
18 V or above Not OK: Abnormal

Not OK Refer to “Check the wire harness conduction:”.

OK Replace the EGR valve.

86E-7 – 98E-7 Series 16-97

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Actuator

3. Check the wire harness conduction:

1- Remove the wire harness from the EGR valve and the E-ECU.
2- Perform the wire harness conduction check between the terminal 1 and the terminal 2 in the below table while
referring to P16-4 "E-ECU pin layout diagram".
Reference: EGR valve conduction check pattern 1

Terminal 2 (EGR valve

Terminal 1 (E-ECU side
side wire harness con- Conduction Condition
wire harness connector)
nector)
Yes OK: Normal
K01/K03/K05 EGR valve terminal C
No Not OK: Abnormal
Yes OK: Normal
K02/K04/K06 EGR valve terminal D
No Not OK: Abnormal
Yes OK: Normal
K54*1 EGR valve terminal A
No Not OK: Abnormal
Yes OK: Normal
K76*1 EGR valve terminal B
No Not OK: Abnormal

*1: Although it is not a battery line, the abnormal signal may be transmitted due to open circuit/short circuit. Check for precaution.

Reference: EGR valve conduction check pattern 2

Terminal 1 (EGR valve

Terminal 2 (E-ECU side
side wire harness con- Conduction Condition
wire harness connector)
nector)
All terminals except for the Yes Not OK: Abnormal
EGR valve terminal C below:
No OK: Normal
K01, K03, K05
All terminals except for Yes Not OK: Abnormal
EGR valve terminal D
GND No OK: Normal
All terminals except for Yes Not OK: Abnormal
EGR valve terminal A*1
K54 No OK: Normal
All terminals except for Yes Not OK: Abnormal
EGR valve terminal B*1
K76 No OK: Normal

*1: Although it is not a battery line, the abnormal signal may be transmitted due to open circuit/short circuit. Check for precaution.

Not OK Interrupted or short circuited between the wire harnesses. Replace the wire harness.
• A coupler failure between the ECU and the wire harness may be caused. Replace the wire harness.
OK
• Replace the E-ECU.

16-98 86E-7 – 98E-7 Series

Actuator METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

■ EGR valve
 Related DTC
Failure Failure phenomenon
#B0403 Open Circuit Between the EGR Motor Coils
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1405 Short Circuit Between the EGR Motor Coils
code (DTC) (Display of screen)

Failure Failure phenomenon

#B0488 EGR Position Sensor Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1409 EGR Feedback Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B148A EGR Stuck Open Valve Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B049D EGR Initialization Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#BG401 EGR ECM Data Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#BH401 EGR Target Value Out of Range
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1410 EGR High Temperature Thermistor Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1411 EGR Low Temperature Thermistor Error
code (DTC) (Display of screen)

86E-7 – 98E-7 Series 16-99

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Actuator

 Workflow
Note: For the work details, refer to “Work description” below.

ࠋ
Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault

Currently trouble is occurring

Failure diagnosis operation

No
1. Replace the EGR valve Replace the E-ECU

OK
Check of the current fault indication by the machine monitor

050234-00EN00

 Work description
1. Replace the EGR valve
There is a possibility of the internal circuit failure of the EGR valve.
Replace the EGR valve.

Not OK Replace the E-ECU.

OK Check of the current fault indication by the machine monitor

16-100 86E-7 – 98E-7 Series

Communication related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

Communication related

■ CAN1
 Related DTC
Failure Failure phenomenon
#BG10B CAN1 (for EGR): Reception Time Out
code (DTC) (Display of screen)

Failure Failure phenomenon Exhaust throttle (CAN message from the exhaust throttle
#BH107
code (DTC) (Display of screen) time out)

 Workflow
Note: For the work details, refer to “Work description” below.
ࠋ
Initial diagnosis by the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault

Currently trouble is occurring

Failure diagnosis operation

Charge the battery

1. Check the No or
battery voltage
replace the battery

OK

2. Check the wire OK

harness conduction Replace the harness
(harness)

No

Turn on and off the power switch

Repeat

3. This is the same

operation as the above
initial diagnosis
Check the actions of
No the other E-ECU
or
replace the E-ECU

045712-00EN01

86E-7 – 98E-7 Series 16-101

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Communication related

 Wiring diagram

A-B Wire harness side coupler

(welding surface)

B42 B00B K76 K54

Junction coupler
EGR valve E-ECU
1 2
A K54
CAN1H

B K76
CAN1L

Sensor side junction coupler E-ECU side junction coupler

1 2
(connection surface) (connection surface)

K54 K76 K76 K54

: Check points
045713-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

16-102 86E-7 – 98E-7 Series

Communication related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Check the battery voltage:
Turn on the power switch and check the battery voltage.
1- Check whether or not the battery voltage is reduced due to the battery life.
2- Check whether or not the battery output is too high.

Not OK Charge or replace the battery.

OK Refer to “Check the wire harness conduction:”

2. Check the wire harness conduction:

1- Remove the wire harness from the machine controller and the E-ECU.
2- Perform the wire harness conduction check between the terminal 1 and the terminal 2 in the below table while
referring to P16-4 "E-ECU pin layout diagram".
Reference: CAN1 line conduction check pattern 1

Terminal 2 (Machine con-

Terminal 1 (E-ECU side
troller wire harness con- Conduction Condition
wire harness connector)
nector)
Machine controller Yes OK: Normal
K54
terminal A No Not OK: Abnormal
Machine controller Yes OK: Normal
K76
terminal B No Not OK: Abnormal

Reference: CAN1 line conduction check pattern 2

Terminal 1 (E-ECU side Terminal 2 (E-ECU side

Conduction Condition
wire harness connector) wire harness connector)
All terminals except for Yes Not OK: Abnormal
K54
K54 and K76 No OK: Normal
All terminals except for Yes Not OK: Abnormal
K76
K54 and K76 No OK: Normal

Not OK Interrupted or short circuited between the wire harnesses. Replace the wire harness.
OK Refer to “Work by the machine monitor”

3. Work by the machine monitor:

1- Turn off the power switch. Turn on the power switch and start the engine.
2- Check if any error is detected and indicated at present by the failure display of the machine monitor.

No Normal
• Check the operation of the other ECU.
Applied
• Replace the E-ECU.

86E-7 – 98E-7 Series 16-103

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Communication related

■ CAN2
 Related DTC
Failure Failure phenomenon
#BG292 TSC1 (CAN Message) Reception Time Out (SA1)
code (DTC) (Display of screen)

Failure Failure phenomenon

#BH301 TSC1 (CAN Message) Reception Time Out (SA2)
code (DTC) (Display of screen)

Failure Failure phenomenon

#BH292 Y_ECR1 (CAN Message) Reception Time Out
code (DTC) (Display of screen)

Failure Failure phenomenon

#BH293 Y_EC (CAN Message) Reception Time Out
code (DTC) (Display of screen)

Failure Failure phenomenon

#BH294 —
code (DTC) (Display of screen)

Failure Failure phenomenon

#BH296 —
code (DTC) (Display of screen)

Failure Failure phenomenon

#BH298 —
code (DTC) (Display of screen)

Failure Failure phenomenon

#BG168 —
code (DTC) (Display of screen)

Failure Failure phenomenon

#BK002 —
code (DTC) (Display of screen)

Failure Failure phenomenon

#BH300 —
code (DTC) (Display of screen)

Failure Failure phenomenon

#BH303 Y_DPFIF (CAN Message) Reception Time Out
code (DTC) (Display of screen)

Failure Failure phenomenon

#BH302 —
code (DTC) (Display of screen)

16-104 86E-7 – 98E-7 Series

Communication related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Workflow
Note: For the work details, refer to “Work description” below..
ࠋ
Initial diagnosis by the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault

Currently trouble is occurring

Failure diagnosis operation

Charge the battery

1. Check the No or
battery voltage
replace the battery

OK

2. Check the wire OK

harness conduction Replace the harness
(harness)

No

Turn on and off the power switch

Repeat

3. This is the same

operation as the above
initial diagnosis
Check the actions of
No the other E-ECU
or
replace the E-ECU

045712-00EN01

 Wiring diagram
Machine controller E-ECU
A K75
CAN2H

B K53
CAN2L

: Check points
045714-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

86E-7 – 98E-7 Series 16-105

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Communication related

 Work description
1. Check the battery voltage:
Turn on the power switch and check the battery voltage.
1- Check whether or not the battery voltage is reduced due to the battery life.
2- Check whether or not the battery output is too high.

Not OK Refer to “Check the wire harness conduction:”

OK Check the actions of the other E-ECU.

2. Check the wire harness conduction:

1- Remove the wire harness from the machine controller and the E-ECU.
2- Perform the wire harness conduction check between the terminal 1 and the terminal 2 in the below table while
referring to P16-4 "E-ECU pin layout diagram".
Reference: CAN2 line conduction check pattern 1

Terminal 2 (Machine con-

Terminal 1 (E-ECU side
troller wire harness con- Conduction Condition
wire harness connector)
nector)
Machine controller Yes OK: Normal
K75
terminal A No Not OK: Abnormal
Machine controller Yes OK: Normal
K53
terminal B No Not OK: Abnormal

Reference: CAN2 line conduction check pattern 2

Terminal 1 (E-ECU side Terminal 2 (E-ECU side

Conduction Condition
wire harness connector) wire harness connector)
All terminals except for Yes Not OK: Abnormal
K75
K75 No OK: Normal
All terminals except for Yes Not OK: Abnormal
K53
K53 No OK: Normal

Not OK Interrupted or short circuited between the wire harnesses. Replace the wire harness.
OK Refer to “Work by the machine monitor:”

3. Work by the machine monitor:

1- Turn off the power switch. Turn on the power switch and start the engine.
2- Check if any error is detected and indicated at present by the failure display of the machine monitor.

No Normal
• Check the operation of the other ECU.
Applied
• Replace the E-ECU.

16-106 86E-7 – 98E-7 Series

ECU related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

ECU related

 Related DTC
Failure Failure phenomenon
#B0601 EEPROM Memory Deletion Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B160E EEPROM Memory Read Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B160F EEPROM Memory Writing Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B2228 Ambient Pressure Sensor Error (Low Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B2229 Ambient Pressure Sensor Error (High Voltage)
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1231 Ambient Pressure Sensor Characteristic Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1613 CY146 SPI Communication Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1608 Excessive Voltage of Supply 1
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1617 Insufficient Voltage of Supply 1
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1469 AD Converter Error 1
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1470 AD Converter Error 2
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1471 External Monitoring IC and CPU Error 1
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1472 External Monitoring IC and CPU Error 2
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1473 ROM Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1474 Shutoff Path Error 1
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1475 Shutoff Path Error 2
code (DTC) (Display of screen)

86E-7 – 98E-7 Series 16-107

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS ECU related

Failure Failure phenomenon

#B1476 Shutoff Path Error 3
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1477 Shutoff Path Error 4
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1478 Shutoff Path Error 5
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1479 Shutoff Path Error 6
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1480 Shutoff Path Error 7
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1481 Shutoff Path Error 8
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1482 Shutoff Path Error 9
code (DTC) (Display of screen)

Failure Failure phenomenon

#B1483 Shutoff Path Error 10
code (DTC) (Display of screen)

16-108 86E-7 – 98E-7 Series

ECU related METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Workflow
Note: For the details of work, refer to the following “Work description”.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault · E-ECU CPU observation IC fault
· E-ECU CPU fault
Current fault is occurring · E-ECU Flash-ROM fault
· (Circuit) low charge fault
· (Circuit) overcharge fault

Failure diagnosis

ECU power on/off

Repeat

1. The same operation as There is no current fault Check of the

the above initial diagnosis malfunction
The same operation condition

There is a current fault

Replace the E-ECU

044395-01EN00

 Work description
1. Operation by the machine monitor:
1- Turn off the ECU power and then turn the key switch on again.
2- Check if any error is detected and indicated at present by the failure display of the machine monitor.

No Check the fault history indication and if there is an indication, check the malfunction condition.
• Turn the ECU power on and off again and perform operation 1.
Yes
• Replace the E-ECU.

86E-7 – 98E-7 Series 16-109

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Others

Others

■ Overspeed
 Related DTC
Failure Failure phenomenon
#B0219 Overspeed
code (DTC) (Display of screen)

 Workflow
Note: For the details of work, refer to the following <Work description>.

Initial diagnosis with the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault

Current fault is occurring

Failure diagnosis

ECU power on/off

Repeat

There is no DTC in the

1. The same operation as fault history indication Check of the
the above initial diagnosis malfunction
The same operation condition

There is a DTC in the

fault history indication

Replace the E-ECU

or
Replace the injector

044396-01EN00

16-110 86E-7 – 98E-7 Series

Others METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Work description
1. Operation by the machine monitor:
1- Turn off the ECU power and start the engine after turning the power switch on again.
2- Check if any error is detected and indicated at present by the failure display of the machine monitor.

No Check the fault history indication and if there is an indication, check the malfunction condition.
• Turn the ECU power on and off again and perform operation 1.
Yes
• Replace the E-ECU or injector.

86E-7 – 98E-7 Series 16-111

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Others

■ Immobilizer
 Related DTC
Failure Failure phenomenon
#BG167 Immobilizer CAN Communication Error
code (DTC) (Display of screen)

Failure Failure phenomenon

#BG426 Immobilizer System Error
code (DTC) (Display of screen)

16-112 86E-7 – 98E-7 Series

Others METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

 Workflow
Note: For the work details, refer to “Work description” below..
ࠋ
Initial diagnosis by the machine monitor

Check of the
A. Check of the There is a DTC in the fault history indication malfunction
current fault condition
indication

There is a
current fault

Currently trouble is occurring

Failure diagnosis operation

Charge the battery

1. Check the No or
battery voltage
replace the battery

OK

2. Check the wire OK

harness conduction Replace the harness
(harness)

No

Turn on and off the power switch

Repeat

3. This is the same

operation as the above
initial diagnosis
Check the actions of
No the other E-ECU
or
replace the E-ECU

045712-00EN01

 Wiring diagram
Machine controller E-ECU
A K75
CAN2H

B K53
CAN2L

: Check points
045714-00EN00

Note: For the E-ECU pin layout, refer to P16-4.

86E-7 – 98E-7 Series 16-113

METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Others

 Work description
1. Check the battery voltage:
Turn on the power switch and check the battery voltage.
1- Check whether or not the battery voltage is reduced due to the battery life.
2- Check whether or not the battery output is too high.

Not OK Refer to “Check the wire harness conduction:”

OK Check the actions of the other E-ECU.

2. Check the wire harness conduction:

1- Remove the wire harness from the machine controller and the E-ECU.
2- Perform the wire harness conduction check between the terminal 1 and the terminal 2 in the below table while
referring to P16-4 "E-ECU pin layout diagram".
Reference: CAN2 line conduction check pattern 1

Terminal 2 (Machine con-

Terminal 1 (E-ECU side
troller wire harness con- Conduction Condition
wire harness connector)
nector)
Machine controller Yes OK: Normal
K75
terminal A No Not OK: Abnormal
Machine controller Yes OK: Normal
K53
terminal B No Not OK: Abnormal

Reference: CAN2 line conduction check pattern 2

Terminal 1 (E-ECU side Terminal 2 (E-ECU side

Conduction Condition
wire harness connector) wire harness connector)
All terminals except for Yes Not OK: Abnormal
K75
K75 No OK: Normal
All terminals except for Yes Not OK: Abnormal
K53
K53 No OK: Normal

Not OK Interrupted or short circuited between the wire harnesses. Replace the wire harness.
OK Refer to “Work by the machine monitor:”

3. Work by the machine monitor:

1- Turn off the power switch. Turn on the power switch and start the engine.
2- Check if any error is detected and indicated at present by the failure display of the machine monitor.

No Normal
• Check the operation of the other ECU.
Applied
• Replace the E-ECU.

16-114 86E-7 – 98E-7 Series

 TNV Tier 4 Service Manual
Section 17

MECHANICAL SYSTEM
FAILURE DIAGNOSIS
Page
Special Service Tools........................................................................... 17-3
Tier 4 (BOSCH) Compression Inspection Procedures ......................... 17-4
Measured Value and Troubleshooting ................................................. 17-6
Quick Reference Table for Troubleshooting......................................... 17-6

86E-7 – 98E-7 Series 17-1

MECHANICAL SYSTEM FAILURE DIAGNOSIS

17-2 86E-7 – 98E-7 Series

 Special Service Tools MECHANICAL SYSTEM FAILURE DIAGNOSIS

SPECIAL SERVICE TOOLS

13 -0.1
0
16mmx18/1inch
(Whitworth screw thread)

13
ø13

25

82
18
(5)
Compression For measuring compression pressure
gauge Part No.YM129A00-92950

(141)

(1)
(ø16)

68
ø17

R0
.2
17

0
ø7.2 -0.1
043931-00E00

86E-7 – 98E-7 Series 17-3

MECHANICAL SYSTEM FAILURE DIAGNOSIS Tier 4 (BOSCH) Compression Inspection

TIER 4 (BOSCH) COMPRESSION INSPECTION PROCEDURES

1. Warm up the engine.
2. Stop the engine.
3. Remove the high-pressure fuel line assembly.
4. Remove the injector harnesses (couplers) of all cylinders.
5. Remove the injector fuel return hose assembly of all cylinders.
6. Remove the injectors of all cylinders. Fill in the cylinder No. on the injector before removal.
7. Install the injectors and the high-pressure lines of all cylinders in the direction where there is no
influence of the inspection operation.
Install the harnesses (couplers) in the injectors.
8. Connect the service tool (SMARTASSIST-Direct) while the engine key is turned ON. Cut the injector
fuel injection of all cylinder with the active control mode.
9. Install the special-purpose adapter and the
compression gauge to the cylinder you want to
measure.
10. Crank and inspect the engine until the display
of the compression gauge becomes stable.
11. When the compression inspection is complete,
turn OFF the active control, turn OFF the SA-D
communication, turn OFF the engine key.
12. Remove the special-purpose adapter and the
compression gauge to the cylinder you want to
measure. 050405-00X00

13. Insert the injectors to the correct cylinders.

Tighten the injectors.
Note: Be sure to install the injector packings to
all cylinders.
14. Install the injector fuel return hose assembly of all cylinders.
15. Install the injector harnesses (couplers) of all cylinders.
16. Install the new high-pressure fuel line assembly.
17. Open the cock of the fuel system.
18. Test the engine. Check for the fuel leaks.
Note: Take care not to adhere or mix the foreign matter when you install the injector, rail, and high-
pressure fuel line.

17-4 86E-7 – 98E-7 Series

 Tier 4 (BOSCH) Compression Inspection MECHANICAL SYSTEM FAILURE DIAGNOSIS

■ Standard compression pressure (reference value)

Compression pressure at 250 min-1 Deviation between
Engine model
Standard Limit cylinders
3D88E-7
S3D86E-7
4D88E-7 3.14 - 3.34 MPa 2.45 - 2.65 MPa 0.2 - 0.3 MPa
S4D86E-7 (32 - 34 kgf/cm2) (25 - 27 kgf/cm2) (2 - 3 kgf/cm2)
4D98E-7
S4D98E-7

■ Engine speed and compression pressure (use for reference)

4.0

S4D98E-7
3.5
Compression pressure (MPa)

4D98E-7

3D88E-7
4D88E-7 S3D86E-7
S4D86E-7
3.0

2.5

2.0
150 200 250 300 350 400 450
Engine speed (min-1) 050977-00EN00

Figure 17-1

86E-7 – 98E-7 Series 17-5

MECHANICAL SYSTEM FAILURE DIAGNOSIS Measured Value and Troubleshooting

MEASURED VALUE AND TROUBLESHOOTING

When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.

No. Item Cause Corrective action

Clogged element Clean the element.
1 Air cleaner element Broken element
Replace the element.
Defect at element seal portion
2 Valve clearance Excessive or no clearance Adjust the valve clearance.
3 Valve timing Incorrect valve clearance Adjust the valve clearance.
Replace the gasket.
4 Cylinder head gasket Gas leak from gasket Retighten the cylinder head bolts to the specified
torque.
Intake/exhaust valve Sticking valve Replace the intake/exhaust valve.
5 Gas leak due to worn valve seat or
Valve seat Lap the valve seat.
foreign matter trapped in valve
Piston
6 Piston ring Gas leak due to scratching or wear Perform honing and use an oversized part.
Cylinder

QUICK REFERENCE TABLE FOR TROUBLESHOOTING

The following table summarizes the general trouble symptoms and their causes. If any trouble symptom
occurs, take corrective action before it becomes a serious problem so as not to shorten the engine service
life.
For details of troubleshooting on electronic control (ECU), refer to the Section 15 and 16.

17-6 86E-7 – 98E-7 Series

Failure Diagnostic List TNV Tier 4 Service Manual FAILURE DIAGNOSTIC LIST MECHANICAL SYSTEM FAILURE DIAGNOSIS
Failure Diagnostic List
Note: Some of the caution lamps are not equipped with some models.

Defective start Engine stall Defective rotation control Insufficient Noise/vibration Lubricant Cooling Intake Exhaust Fuel Electrics/electronics
Symptoms and conditions of failures after start engine output water
Starter not Starter Exhaust

Speed change by accelerator not available (constant speed)

rotate rotates fume Without load At work Exhaust color At work

ECU indicator lamp not on just after key-on (2 seconds)

ECU indicator lamp on just after key-on (2 seconds)

Fuel mixed with water (oil-water separator lamp on)

Engine not start (stall after serial combustion)
Engine not start (not even initial combustion)

Prescribed ECU control function not operate

ECU indicator lamp not on just after key-on

Oil pressure too low (oil pressure lamp on)

Fuse meltdown, disconnection (repeated)

Noise other than combustion from engine

Overheated (water temperature lamp on)

Battery charge defect (charge lamp on)

Knocking noise at combustion too high
Specified speed setting not available

Pressure down (air cleaner lamp on)

Action Referenced page number

Fuel filter contaminated too early

Lubricant consumption too much
Return to low speed not smooth
Engine starts later than ever

ECU indicator lamp flashing

Fuel consumption too much
Lubricant mixed with water

Water temperature too low

Combustion noise uneven

Lubricant diluted with fuel

Exhaust temperature up
Engine vibration too big

White exhaust color

Black exhaust color

Blow-by too much

Poor acceleration

Pressure up
Hunting

Hunting

Normal

White
Much

Black
None

Little
Cause

Intake/exhaust valve clearance      

Valve clearance adjustment See Measuring and Adjusting Valve
incorrect Clearance on page 6-42
Valve seat facing See Valve face and valve seat on
Compression failure at valve seat         
page 6-36.
Correction or replacement of See Removal of intake/exhaust valves on
Intake/exhaust valve seizure           
intake/exhaust valve page 6-32.
Gasket replacement See Removal of cylinder head on
Cylinder head gasket blow-out   
page 6-31.
Piston ring replacement See Reassembly of pistons on
Piston ring sticking or breakage            
page 6-61.
Horning work and usage of over-sized See Honing and Boring on page 6-60.
Wear of piston ring, piston or cylinder       
parts
Seizure of crank pin metal or bearing Repair or replacement See Inspection of crankshaft on
       page 6-57.
parts
Engine system

Correction of closed gap position See Reassembly of pistons on

Closed gap position fault of piston ring    
page 6-61.
Correction of assembling See Reassembly of pistons on
Reverse assembling of piston ring    
page 6-61.
Wear of crank pin metal and journal Measurement and replacement See Inspection of crankshaft on
      page 6-57.
metal
Tightening at specified torque See Torque for Bolts and Nuts on
Connecting rod bolt loose   
page 6-17.
Foreign material entered into    
Disassembling and repair See Disassembly of Engine on
combustion chamber page 6-45.
Gear mesh adjustment See Checking timing gear backlash on
Gear backlash too big 
page 6-46.
Measurement and replacement See Inspection of valve guides on
Wear of intake/exhaust valve guide   
page 6-34.
Open/close timing failure of      
Valve clearance adjustment See Measuring and Adjusting Valve
intake/exhaust valve Clearance on page 6-42.
Engine vibration isolating support Repair or replacement of faulty parts
   
loose, damage
Blower contamination    Blower cleaning See Washing Procedure on page 10-10.
Turbocharger

Disassembling and inspection See Waste Gate Valve Test on

Operation defect of waste gate   
page 10-13.
Disassembling and inspection See Radial bearing on page 10-9.
Wear of radial metal   

86E-7 – 98E-7 Series 17-7

MECHANICAL SYSTEM FAILURE DIAGNOSIS Failure Diagnostic List

Engine stall Insufficient Cooling

Symptoms and conditions of failures Defective start after start Defective rotation control engine output Noise/vibration Lubricant water Intake Exhaust Fuel Electrics/electronics

Starter not Starter Exhaust

Speed change by accelerator not available (constant speed)

rotate rotates fume Without load At work Exhaust color At work

ECU indicator lamp not on just after key-on (2 seconds)

ECU indicator lamp on just after key-on (2 seconds)

Fuel mixed with water (oil-water separator lamp on)

Engine not start (stall after serial combustion)
Engine not start (not even initial combustion)

Prescribed ECU control function not operate

ECU indicator lamp not on just after key-on

Oil pressure too low (oil pressure lamp on)

Fuse meltdown, disconnection (repeated)

Noise other than combustion from engine

Overheated (water temperature lamp on)

Battery charge defect (charge lamp on)

Knocking noise at combustion too high
Specified speed setting not available

Pressure down (air cleaner lamp on)

Action Referenced page number

Fuel filter contaminated too early

Lubricant consumption too much
Return to low speed not smooth
Engine starts later than ever

ECU indicator lamp flashing

Fuel consumption too much
Lubricant mixed with water

Water temperature too low

Combustion noise uneven

Lubricant diluted with fuel

Exhaust temperature up
Engine vibration too big

White exhaust color

Black exhaust color

Blow-by too much

Poor acceleration

Pressure up
Hunting

Hunting

Normal

White
Much

Black
None

Little
Cause

Thermostat replacement See Disassembly of Engine Coolant

Radiator super cooled   
Pump on page 8-7.
Cooling water system

Thermostat replacement See Disassembly of Engine Coolant

Insufficient radiator cooling   
or check for fan belt loose Pump on page 8-7.
Water leak inspection of cooling water See Engine Coolant System Check on
Insufficient cooling water quantity   
system page 8-6.
Repair or replacement See Disassembly of Engine Coolant
Water jacket cracks   
Pump on page 8-7.
Fan belt elongation    Adjustment of belt tension
Inspection or replacement See Disassembly of Engine Coolant
Thermostat fault    
Pump on page 8-7.
Usage of correct lubricant See Engine Oil Specifications on
Incorrect lubricant      
page 4-22.
Repair See Disassembly of Oil Pump on
Lubricant system leakage  
Lubricant system

page 9-7.
Insufficient discharge rate of trochoid 
Inspection and repair See Disassembly of Oil Pump on
pump page 9-7.
Lubricant filter clogged   Cleaning or replacement
Cleaning, adjustment or replacement See Disassembly of Oil Pump on
Regulator valve fault 
page 9-7.
Insufficient lubricant quantity   Replenishment of correct lubricant See Adding Engine Oil on page 4-23.
Excess filling into crankcase    Engine oil check See Adding Engine Oil on page 4-23.
Usage of correct fuel See Diesel Fuel Specifications on
Incorrect fuel        
page 4-19.
Water entered into fuel system          Drainage of fuel filter
Fuel filter clogged      Cleaning or replacement
Bleeding See Priming the Fuel System on
Air entered into fuel system      
page 4-21.
Fuel system

Fuel pipe clogged, cracked    Cleaning or replacement

Insufficient fuel feeding to fuel supply     
Check of fuel tank cock, fuel filter, fuel
pump pipe, fuel feed pump
Valve in priming pump pinched dust See Fuel System Components on
Priming not available 
(disassembled cleaning) page 7-8.
Strainer at feed pump inlet clogged    Cleaning of strainer
Check of fuel tank and cap, as well as
Sealing defect of fuel tank   installation of
genuine parts
Air filter clogged         Cleaning of air filter
Intake

Engine operation at high temperature     

Consideration of matching output
or high land reduction with load
Exhaust pipe clogged       Cleaning of exhaust pipe

17-8 86E-7 – 98E-7 Series

Failure Diagnostic List MECHANICAL SYSTEM FAILURE DIAGNOSIS
Engine stall Insufficient Cooling
Symptoms and conditions of failures Defective start after start Defective rotation control engine output Noise/vibration Lubricant water Intake Exhaust Fuel Electrics/electronics

Starter not Starter Exhaust

Speed change by accelerator not available (constant speed)

rotate rotates fume Without load At work Exhaust color At work

ECU indicator lamp not on just after key-on (2 seconds)

ECU indicator lamp on just after key-on (2 seconds)

Fuel mixed with water (oil-water separator lamp on)

Engine not start (stall after serial combustion)
Engine not start (not even initial combustion)

Prescribed ECU control function not operate

ECU indicator lamp not on just after key-on

Oil pressure too low (oil pressure lamp on)

Fuse meltdown, disconnection (repeated)

Noise other than combustion from engine

Overheated (water temperature lamp on)

Battery charge defect (charge lamp on)

Knocking noise at combustion too high
Specified speed setting not available

Pressure down (air cleaner lamp on)

Action Referenced page number

Fuel filter contaminated too early

Lubricant consumption too much
Return to low speed not smooth
Engine starts later than ever

ECU indicator lamp flashing

Fuel consumption too much
Lubricant mixed with water

Water temperature too low

Combustion noise uneven

Lubricant diluted with fuel

Exhaust temperature up
Engine vibration too big

White exhaust color

Black exhaust color

Blow-by too much

Poor acceleration

Pressure up
Hunting

Hunting

Normal

White
Much

Black
None

Little
Cause

Inspection and replacement of fuse For harness inspection method,

Fuse meltdown, disconnection      Repair or replacement of harness see MeCHANICAL SYSTEM Failure
Diagnosis on page 17-1.
Starter fault   Repair or replacement of starter See Starter Motor on page 11-8.
Repair or replacement of alternator See Removal of Alternator on
Alternator fault  
page 12-10.
Repair or replacement of harness
Wiring disconnection        
disconnection
Wiring short-circuit (insulator broken), Inspection, repair or replacement of
electric power load of added device too   harnesses
big Review of added devices

Battery voltage descent   - Inspection and charging of battery

Repair or replacement of harness For harness inspection method,
Key switch fault, disconnection    Key switch replacement see MeCHANICAL SYSTEM Failure
Diagnosis on page 17-1.
Instantaneous interruption of key  
Key switch replacement
switch
Failure, disconnection, short-circuit of Repair or replacement of harness For harness inspection method,
 Replacement of starter relay see MeCHANICAL SYSTEM Failure
Electric system

starter relay Diagnosis on page 17-1.

Main relay fault Repair or replacement of harness For harness inspection method,
(Error other than contact sticking that   Replacement of main relay see MeCHANICAL SYSTEM Failure
ECU can’t detect) Diagnosis on page 17-1.

Actuator relay fault Replacement of actuator relay

  
(Error of contact that ECU can’t detect)
The start assist relay may be faulty.    
Replacement of start assist relay
(Error of contact that ECU can’t detect)
Accelerator sensor signal error    
Repair or replacement of accelerator Monitor the accelerator sensor by the
(Error at which level ECU can’t detect) sensor machine monitor.
Water temperature sensor signal error Replacement of water temperature Monitor the cooling water temperature by
     sensor the machine monitor.
(Error at which level ECU can’t detect)
Speed sensor signal error Cleaning or replacement of speed sensor Monitor the engine rotational speed by
(Cause of noise etc. that ECU can’t       Repair or replacement of fuel supply the machine monitor.
detect) pump

Rack position sensor signal error Repair or replacement of fuel supply Monitor the rack position sensor signal by
      pump the machine monitor.
(Level that ECU can’t detect)
Operation defect of rack actuator      
Repair or replacement of fuel supply Check the movement of rack actuator by
(Level that ECU can’t detect) pump the machine monitor.
Replace the lamp.
ECU failure lamp disconnected  Repair or replace the harness.
ECU faulty (ECU self diagnosis failure)      Replace the ECU.

86E-7 – 98E-7 Series 17-9

MECHANICAL SYSTEM FAILURE DIAGNOSIS Failure Diagnostic List

Engine stall Insufficient Cooling

Symptoms and conditions of failures Defective start after start Defective rotation control engine output Noise/vibration Lubricant water Intake Exhaust Fuel Electrics/electronics

Starter not Starter Exhaust

Speed change by accelerator not available (constant speed)

rotate rotates fume Without load At work Exhaust color At work

ECU indicator lamp not on just after key-on (2 seconds)

ECU indicator lamp on just after key-on (2 seconds)

Fuel mixed with water (oil-water separator lamp on)

Engine not start (stall after serial combustion)
Engine not start (not even initial combustion)

Prescribed ECU control function not operate

ECU indicator lamp not on just after key-on

Oil pressure too low (oil pressure lamp on)

Fuse meltdown, disconnection (repeated)

Noise other than combustion from engine

Overheated (water temperature lamp on)

Battery charge defect (charge lamp on)

Knocking noise at combustion too high
Specified speed setting not available

Pressure down (air cleaner lamp on)

Action Referenced page number

Fuel filter contaminated too early

Lubricant consumption too much
Return to low speed not smooth
Engine starts later than ever

ECU indicator lamp flashing

Fuel consumption too much
Lubricant mixed with water

Water temperature too low

Combustion noise uneven

Lubricant diluted with fuel

Exhaust temperature up
Engine vibration too big

White exhaust color

Black exhaust color

Blow-by too much

Poor acceleration

Pressure up
Hunting

Hunting

Normal

White
Much

Black
None

Little
Cause

Not failure Check the causes of engine stop or

ECU control function operating    
Implement regular usage starter restraint by a machine monitor.

Disconnection/short-circuit of water Repair or replacement of harness For harness inspection method,

   Replacement of water temperature see MeCHANICAL SYSTEM Failure
temperature sensor sensor Diagnosis on page 17-1.
Repair or replacement of harness For harness inspection method,
by ECU failure diagnosis function

Disconnection/short-circuit of  
Engine stop or operation limits

Replacement of accelerator sensor see MeCHANICAL SYSTEM Failure

accelerator sensor Diagnosis on page 17-1.
Repair or replacement of harness For harness inspection method,
Speed sensor signal error    Repair or replacement of fuel supply see MeCHANICAL SYSTEM Failure
pump Diagnosis on page 17-1.
Check operating machine’s driving.
Engine over speed  
Check speed sensor signal.
Repair or replacement of harness For harness inspection method,
CAN communication error    ECU Replacement see MeCHANICAL SYSTEM Failure
Diagnosis on page 17-1.

Disconnection/short-circuit of EGR Repair or replacement of harness For harness inspection method,

   Replacement of EGR valve see MeCHANICAL SYSTEM Failure
valve motor Diagnosis on page 17-1.

Disconnection/short-circuit of start Repair or replacement of harness For harness inspection method,

    Relay replacement see MeCHANICAL SYSTEM Failure
assist relay Diagnosis on page 17-1.
Main relay “OFF” not available   Relay replacement
Malfunction by ECU self-diagnosis   ECU Replacement

17-10 86E-7 – 98E-7 Series

86E-7 – 98E-7 SERIES ENGINE

Form No. SEN06575-02

©2019 KOMATSU
All Rights Reserved
Printed in Japan 07-19 (01)