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Diesel Injection Pump

SERVICE MANUAL
Common Rail System for The MITSUBISHI FUSO FIGHTER 6M60 Engine
OPERATION
April, 2004

00400071E

2004 DENSO CORPORATION All Rights Reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of the publisher.

TABLE OF CONTENTS
1. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. PRODUCT APPLICATION LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2-1. Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2-2. Component Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3. GENERAL DESCRIPTION OF MAIN NEW FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3-1. Common Rail Specifications and Engine Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3-2. System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4. MAIN FUNCTIONAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-1. Changes to the Main Functional Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-2. Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4-3. Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4-4. Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4-5. Sensor Additions and Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 5. CONTROL OPERATION CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5-1. Idle-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6. ECU RELATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 6-1. External Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 6-2. Terminal Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6-3. Terminal Symbol Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 7. DIAGNOSTIC TROUBLE CODES (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 7-1. DIAGNOSTIC TROUBLE CODES LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.

GENERAL DESCRIPTION
This manual describes the common rail system installed in the 6M60 engine of the Mitsubishi Fuso Fighter. The most significant difference to the conventional common rail system is that this system employs a compact and lightweight HP4 supply pump, and a G2 injector with better response. For more details on the common rail system, refer to service manual No. 00400041 "Common Rail System for HINO J05D/J08E Type Engine", issued in October 2003.

1-1. Outline

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2.

PRODUCT APPLICATION LIST

2-1. Vehicle Specifications


Vehicle Name Mitsubishi Fuso Fighter Engine Model 6M60 Engine Displacement 7,545 cc Remarks

2-2. Component Part Numbers


Part Name Injector Rail Flow Damper Pressure Limiter Pc sensor Supply Pump ECU 294050-0050 275800-3401 275800-3411 275800-3451 Boost Pressure Sensor TDC (MRE) Sensor NE (MPU) Sensor Intake Air Temperature Sensor Fuel Temperature Sensor Accelerator Position Sensor 179730-0030 198300-7030 MC885579 ME162376 079800-5580 949979-1420 029600-0570 071500-2571 DENSO P/N 095000-5450 095440-0570 Mitsubishi P/N ME302143 ME302292 ME743861 ME743862 ME743864 ME302145 ME302751 ME302752 ME302986 MK369080 ME301026 MC885578 ME352426 12V Specification 6M60T1 6M60T2 6M60T1 (Allison AT) Rail Component Parts Remarks

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3.

GENERAL DESCRIPTION OF MAIN NEW FEATURES

3-1. Common Rail Specifications and Engine Elements


FK6 Common Rail Specifications Main Elements Pressure Used Engine Elements Model Engine Displacement Output Torque HP-4 + G2 170MPa L6, TI, 4 valves. 7.5L 199kW/2700rpm 785Nm/1400rpm

3-2. System Configuration A. Overall System


Pressure limiter Rail Rail pressure sensor

Engine ECU

Injector

Filter

Fuel temperature sensor

Supply pump

Fuel tank SCV (Suction Control Valve)


Q000660E

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4.

MAIN FUNCTIONAL PARTS


This section describes only the functional parts that have changed significantly.

4-1. Changes to the Main Functional Parts 4-2. Supply Pump A. Changes
Significant changes are listed below. Model Rotation Ratio Np : Ne Maximum Speed Direction of Rotation Component Parts SCV Feed Pump Rated Voltage Type Plunger Diameter No. Lift Amount Fuel Temperature Sensor HP-4 1:1 4000rpm Counter clockwise (viewed from actuating side). Trochoid Type 12V Normally Open 8.5 3 8.8mm 2.45 0.24k (20C)

B. External View

SCV Fuel temperature sensor

Q000662E

C. Construction and Operation


The ring cam is press fitted into an eccentric position relative to the cam shaft. The ring cam is a triple-lobed cam.

Feed pump

SCV

Camshaft

Plunger

Ring cam

Q000663E

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As the camshaft makes one rotation, the positional relationship between the ring cam and the plunger remains unchanged. Each plunger makes a single reciprocal movement to pump the fuel. Fuel is drawn in by the feed pump, and the suction quantity is adjusted by the SCV (Suction Control Valve).

Plunger #1 Highest Point


Plunger #2 [Ring cam and eccentric cam details] Plunger Plunger #1 Camshaft

Plunger #3

Eccentric cam

Ring cam

Camshaft rotates 120 clockwise when viewed from the opposite side of the actuating side

Plunger #3 Highest Point

Plunger #2 Highest Point

Camshaft rotates a further 120 clockwise when viewed from the opposite side of the actuating side
Q000664E

4-3. Rail A. External View


Rail pressure sensor

Pressure limiter

Flow limiter High-pressure fuel inlet to Fuel tank to Injector to Injector

Q000665E

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B. Rail Pressure Sensor


The basic principles and construction are the same as for the conventional model. The pressure detection range has been changed to accommodate the increase in pumping pressure from the supply pump.

VOUT 4.2 3.6 2.6

Atmospheric temperature: 25C VC=5V

VC

VOUT GND

1.3 1.0 0

0 20

100

160 200
Q000666E

Rail pressure (MPa)

C. Flow Limiter
A flow limiter is employed instead of a flow damper. As with the flow damper, the flow limiter closes the fuel passage to prevent further flow of fuel in the event of an excessive fuel flow. If an abnormal flow occurs, the high pressure forces the piston up. This closes the fuel passage leading to the seat.

to Injector Body

Spring

Piston

Stopper
Q000667E

D. Pressure Limiter
The construction and operating principles are the same as for the conventional model. The operating pressure has changed.

Open valve pressure: 2219MPa


Housing Valve guide Valve

Rail side

Valve body Spring


Q000668E

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4-4. Injector A. Outline


A compact, energy-saving solenoid-control type TWV (Two-Way Valve) injector has been adopted.

B. Construction

Solenoid valve

High-pressure fuel (from rail)

Control chamber

Command piston

Nozzle spring Pressure pin Nozzle needle Seat

High-pressure fuel

Leak passage

Q000669E

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C. Operation
The TWV (Two-Way Valve) solenoid valve opens and closes the outlet orifice passage to control both the pressure in the control chamber, and the start and end of injection. a. Non-Injection When no current is supplied to the solenoid, the TWV (solenoid valve) is pushed downward by the spring, closing the outlet orifice. This equalizes the control chamber pressure forcing the command piston down and the pressure forcing the nozzle needle up. A state of non-injection results because the nozzle needle closes due to the nozzle spring force and the difference in areas to which pressure is being applied. b. Injection When current is initially applied to the solenoid, the attraction of the solenoid pulls the TWV (solenoid valve) up, opening the outlet orifice and allowing fuel to flow out of the control chamber. After the fuel flows out, pressure in the control chamber decreases, pulling the command piston up. This causes the nozzle needle to rise and injection to start. c. End of Injection When current continues to be applied to the solenoid, the nozzle reaches its maximum lift, where the injection rate is also at the maximum level. When current to the solenoid is turned OFF, the TWV (solenoid valve) falls and closes the orifice. Fuel then flows into the control chamber via the inlet orifice, increasing pressure and causing the nozzle needle to close immediately and injection to stop.

Solenoid TWV

Actuating current

Actuating current

Actuating current

Outlet orifice Inlet orifice Command piston

Rail

Control chamber pressure

Control chamber pressure

Control chamber pressure

Nozzle

Injection rate

Injection rate

Injection rate

Non-injection

Injection

Injection ends
QD0717E

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4-5. Sensor Additions and Changes A. Cylinder Recognition Sensor (TDC Sensor)
The cylinder recognition sensor is an MRE (Magneto Resistive Element) type. As the teeth in the cylinder recognition sensor pass the sensor, the magnetic resistance in the sensor changes. The change in the voltage generated is converted into a rectangular wave pulse in the IC circuit, and this signal is output to the engine ECU. A cylinder recognition pulsar is installed to the engine camshaft gear, and it outputs the cylinder recognition signal.

TDC (cylinder recognition) sensor

Q000680E

The No. 1 cylinder is located 78CA from the No. 1 TDC reference signal following the irregular pulse. The interval between each cylinder is the same degree.

0CA NE+ (NE-reference)

120CA #5TDC

240CA #3TDC

360CA #6TDC

480CA #2TDC

600CA #4TDC

720CA #1TDC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

4 missing teeth G (TDC signal) (G-reference) 78CA 78CA 78CA

3CA 78CA 78CA Extra tooth

30CA 78CA

No.1 reference pulse


Q000671E

B. Fuel Temperature Sensor


The fuel temperature sensor is installed on the supply pump. It detects the fuel temperature and sends a signal to the engine ECU. The detection component utilizes a thermistor in which the internal resistance changes according to the temperature. The temperature versus resistance characteristics are shown in the diagram below.

[Resistance Value Characteristics]


Fuel temperature sensor
Temperature (C) -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 Resistance Value (k) (25.4) 15.01.5 (9.16) (5.74) (3.70) 2.450.24(RO) (1.66) (1.15) (0.811) (0.584) (0.428) 0.3180.031 (0.240) (0.1836) (0.1417) (0.1108)

Q000672E

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C. Intake Air Temperature Sensor


This sensor is used to detect the intake air temperature in order to correct the injection quantity, injection timing and injection pressure. Similar to the other temperature sensors, it uses a thermistor. The temperature versus resistance characteristics are shown in the diagram below.

[Temperature - Resistance Characteristics]


Intake air temperature sensor Temperature (C) Resistance Value (k) (-30) (26.758) (-20) -10 20 80 (120) (16.2) 5.880.588 2.450.245 0.3220.0483 (0.1058)

Q000673E

D. Intake Air Pressure Sensor (PIM)


This is a type of semi-conductor pressure sensor. It utilizes the characteristic whereby electrical resistance changes when pressure is applied to silicon crystal. The intake air pressure sensor is used to correct the full load injection quantity data programmed in the engine ECU. The relationship between pressure and output voltage is shown in the diagram below.

[Pressure Characteristics]
Intake air pressure sensor Output voltage (V) 4.500 VC=5V

3.220

GND

PB VC

0.500 66.67 202.67 266.67 Intake air pressure (kPa)


Q000674E

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5.

CONTROL OPERATION CHANGES


If the conditions shown in the diagram on the right overlap, the idling speed is set to a fixed value.

5-1. Idle-Up

A/C switch: ON

Vehicle speed: 0km/h

Neutral switch: ON
Q000677E

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6.

ECU RELATED
*1: For the 6M60T1 engine.

6-1. External Wiring Diagram

Starter switch Meter 15A 5A 5A ISS engine starter relay ISS Starter continuous energization prevention relay 111 to Starter relay 157 158 35 120 Vehicle control ECU ABS/ASR ECU 76 74 75 5 20A 6 7 102 140 73 141 72 18 106 Battery 12V TWV1 (#1 cylinder) Frame ground 107 103 Glow relay Actuation relay TWV3 (#3 cylinder) 104 Glow relay 70 79 80 82 83 84 Diagnosis light 1 Diagnosis light 2 Glow light (For flywheel PTO) A/T ECU Exhaust brake cut SW (For transmission PTO) 85 Exhaust brake lamp Exhaust brake SW Vehicles not equipped with ABS Exhaust brake MV1 48 43 59 Warm-up SW 46 56 Clutch SW Neutral SW

52

ECU

58

ISS ECU

Pilot light

ABS assist brake cut relay ABS ECU

ECU main relay

Fuse

Fuse

Main fuse

TWV5 (#2 cylinder)

105 142 143

Glow plug +12V 27 Pulse divider GND 53 Dual pressure SW Vehicle speed sensor

TWV2 (#5 cylinder)

137

TWV4 (#6 cylinder)

138

Air conditioning SW 10A Magnetic clutch relay

TWV6 (#4 cylinder)

139 40 41 39 133 120 131 126

97 9 11 51 AT ECU

Engine speed sensor

Torque cut SW NE OUT PWM accelerator Idle-up cancel SW PTO relay

+5V Cylinder recognition sensor SIG GND Accelerator position sensor 1

Gear position SW

R D 2 L Meter cluster MV (transmission) PTO SW pilot light

21 134 123

Accelerator position sensor 2

22 136 10

Development output

Accelerator SW EGR MV1 EGR MV2 EGR MV3

61 108 109 110

66 PTO SW 31 26 N correction resistor 57 54 128 Boost sensor PTO accelerator position sensor

Diagnosis memory clear SW AT recognition SW Rail pressure sensor 1 Rail pressure sensor 2 MUT-3 (KWP2000) Diagnosis SW

77 67 125 121 132 135 19 68

30

IMC volume

55 155 Coolant temperature sensor 162 Fuel temperature sensor

62 Quantity correction resistor 8 Tachometer HP-4. Injection pump 163 146 Fuel temperature sensor SCV

154 Intake air temperature sensor

147 144 145

Q000681E

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6-2. Terminal Layout

Q000679E

6-3. Terminal Symbol Explanation A. Terminals No. 1 to 34


No. 1 2 3 4 5 6 7 8 +B +B +B TAC1 Terminal Name +VB +VB +VB Tachometer signal Signal Name No. 18 19 20 21 22 23 24 25 AD1 AD2 AD19 Terminal Name CASEGND KWP2000 Signal Name Case ground MUT-3 Accelerator position sensor 1 Accelerator position sensor 2 Temperature sensor 4 for after-treatment (following EGR merging). 9 10 11 12 13 14 15 16 17 TAC2 POUT1 POUT2 NE OUT Development output (Q-OUT) PWMACC 26 27 28 29 30 31 32 33 34 AD20 VS1 AD14 AD15 IMC volume PTO accelerator position sensor N correction resistor Vehicle speed sensor -

B. Terminals No. 35 to 69
No. 35 36 37 38 39 40 41 42 43 Terminal Name +BF NE-SLD NE+ NEOUT2 NE-SLD Engine speed sensor + Engine speed sensor Relay to prevent continuous starter energization. Signal Name SURGE OUT 1 No. 53 54 55 56 57 58 59 60 61 Terminal Name SW7 A-GND4 A-GND5 SW1 A-VCC4 SW8 SW10 SW17 Accelerator switch Signal Name Air conditioning switch Sensor GND4 Sensor GND5 Key switch Sensor power supply 4 Neutral switch Warm-up switch -

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No. 44 45 46 47 48 49 50 51 52

Terminal Name SW1 SW2 SW3 SW5 SW6 Key switch

Signal Name -

No. 62 63 64

Terminal Name AD21 SW9 SW11 SW16 PTO switch

Signal Name Quantity correction resistor -

Starter switch Exhaust brake switch Idle-up cancel switch Clutch switch 1

65 66 67 68 69

AT recognition switch Diagnosis switch -

C. Terminals No. 70 to 101


No. 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 GND GND OUT17 OUT18 +BF SW27 SW15 S-OUT1 S-OUT2 S-OUT3 S-OUT4 Terminal Name OUT19 ECU analog GND ECU analog GND ECU main relay ECU main relay SURGE OUT 2 Diagnosis memory clear switch Exhaust brake cut switch Diagnosis light 1 (red) Diagnosis light 2 (orange) Glow light Exhaust brake light Signal Name Glow relay actuation relay No. 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 Terminal Name Signal Name -

D. Terminals No. 102 to 136


No. 102 103 104 105 106 107 108 109 Terminal Name P-GND TWV1 TWV3 TWV5 Signal Name POWER GND Injector drive signal 1 Injector drive signal 3 Injector drive signal 5 No. 120 121 122 123 124 125 126 127 Terminal Name G AD4 A-VCC3 A-VCC2 A-VCC1 G sensor + Rail pressure sensor 1 Sensor power supply 3 Sensor power supply 2 Sensor power supply 1 Signal Name

COMMON1 Injector drive power supply 1-1 COMMON1 Injector drive power supply 1-2 -

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No. 110 111 112 113 114 115 116 117 118 119

Terminal Name OUT12 -

Signal Name Exhaust brake MV1 -

No. 128 129 130 131 132 133 134 135 136

Terminal Name AD3 G-GND AD5 G-VCC A-GND1 A-GND2 A-GND3 G sensor

Signal Name Boost sensor -

Rail pressure sensor 2 CAM ANGLE VCC (5V) Sensor GND1 Sensor GND2 Sensor GND3

E. Terminals No. 137 to 167


No. 137 138 139 140 141 142 143 144 Terminal Name TWV2 TWV4 TWV6 P-GND P-GND Signal Name Injector drive signal 2 Injector drive signal 4 Injector drive signal 6 POWER GND POWER GND No. 153 154 155 156 157 158 159 160 AD6 AD7 CAN1H CAN1L CAN1 HIGH CAN1 LOW Terminal Name Signal Name Intake air temperature sensor (before Coolant temperature sensor -

COMMON2 Injector drive power supply 2-1 COMMON2 Injector drive power supply 2-2 SCVLO HP3 and HP4 suction control valve drive signal 1

145

SCVLO

HP3 and HP4 suction control valve drive signal 2

161

146

SCVHI

HP3 and HP4 suction control valve power supply 1

162

AD8

Fuel temperature sensor 1 (leak side)

147

SCVHI

HP3 and HP4 suction control valve power supply 2

163

AD9

Fuel temperature sensor 2

148 149 150 151 152

164 165 166 167

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7.

DIAGNOSTIC TROUBLE CODES (DTC)

7-1. DIAGNOSTIC TROUBLE CODES LIST


DG Code P0107 P0108 P0112 P0113 P0117 P0118 P0121 P0122 P0123 P0187 P0188 P0191 P0192 P0193 P0200 Source Atmospheric pressure sensor Atmospheric pressure sensor Intake air temperature sensor Intake air temperature sensor Coolant temperature sensor Coolant temperature sensor Accelerator position sensor Accelerator position sensor No. 1 Accelerator position sensor No. 1 Fuel temperature sensor Fuel temperature sensor Rail pressure sensor Rail pressure sensor Rail pressure sensor Injector COM1 Malfunction Outline Output from the atmospheric pressure sensor is too low. Output from the atmospheric pressure sensor is too high. Output from the intake air temperature sensor is too low. Output from the intake air temperature sensor is too high. Output from the coolant temperature sensor is too low. Output from the coolant temperature sensor is too high. Output from accelerator position sensors No. 1 and No. 2 is inconsistent. Output from the accelerator position sensor is too low. Output from the accelerator position sensor is too high. Output from the fuel temperature sensor is too low. Output from the fuel temperature sensor is too high. Output from the rail pressure sensor is fixed at a middle value. Output from the rail pressure sensor is too low. Output from the rail pressure sensor is too high. COM1 is open or short circuited; or TWV1, TMV3 or TWV5 is open or short circuited. P0201 P0202 P0203 P0204 P0205 P0206 P0219 P0222 P0223 P0227 P0228 P0234 P0237 P0238 P0251 P0252 P0253 P0254 P0255 Injector TWV Injector TWV Injector TWV Injector TWV Injector TWV Injector TWV Overrun Accelerator position sensor No. 2 Accelerator position sensor No. 2 PTO accelerator position sensor PTO accelerator position sensor Abnormally boost pressure Intake air pressure sensor Intake air pressure sensor Fuel leak Pressure limiter Abnormally high pressure 2 Abnormally high pressure 1 Supply pump Open circuit in the TWV1 wiring or injector coil. Open circuit in the TWV5 wiring or injector coil. Open circuit in the TWV3 wiring or injector coil. Open circuit in the TWV6 wiring or injector coil. Open circuit in the TWV2 wiring or injector coil. Open circuit in the TWV4 wiring or injector coil. Engine is overrunning. Output from the accelerator position sensor is too low. Output from the accelerator position sensor is too high. Output from the PTO accelerator position sensor is too low. Output from the PTO accelerator position sensor is too high. Boost pressure is excessive or insufficient. Output from the intake air pressure sensor is too low. Output from the intake air pressure sensor is too high. Fuel leak in the injection system or fuel system. Pressure limiter is operating. Output from the rail pressure sensor is over the higher upper limit. Output from the rail pressure sensor is over the lower upper limit. Rail pressure exceeds the specified duration or is over the specified value. (Specified speed range.) P0256 Supply pump Rail pressure exceeds the specified duration or is over the specified value (lower pressure and longer duration than PO255). (Medium to high speed range.)

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DG Code P0257 P0335 P0340 P0380 Supply pump

Source

Malfunction Outline Poor pumping in the supply pump No. 1 cylinder. No signal output from the engine speed sensor. No signal output from the TDC sensor. BATT short in the output to the glow relay. Open or GND short in the glow relay output.

Engine speed sensor TDC sensor Glow relay

P0500

Vehicle speed sensor

Open or short circuit in the vehicle speed sensor; frequency is too high; no output.

P0506 P0507 P0510 P0600

IMC volume IMC volume IDLE switch SLD system

IMC volume signal is too low. IMC volume signal is too high. IDLE switch is seized closed. Communication error between the vehicle speed control ECU and engine ECU or vehicle speed sensor.

P0605 P0616 P0617

CPU (in the engine ECU) Starter prohibition relay Starter prohibition relay

Main CPU malfunction or watchdog malfunction. BATT short in the output to the starter prohibition relay. Open circuit (external) or GND short in the output to the starter prohibition relay.

P1121 P1171 P1172 P1176 P1177 P1185 P1200

Intake throttle valve

Open circuit, GND short or BATT short in the output to valve MV1.

Injection correction resistance value Injection correction resistance value is too low. Injection correction resistance value Injection correction resistance value is too high. Maximum speed adjusting resistor Adjusting resistor value is too low. Maximum speed adjusting resistor Adjusting resistor value is too high. Engine stop switch Injector COM2 Engine stop switch is seized closed. COM2 is open or short circuited; or TWV2, TWV4 or TWV6 is open or short circuited.

P1210

Capacitor charging circuit (ECU)

Malfunction in the injector drive power supply circuit (overcharging or insufficient charging).

P1240 P1241 P1242 P1243 P1244 P1245 P1255

Fuel system 1 Fuel system 5 Fuel system 3 Fuel system 6 Fuel system 2 Fuel system 4 Output to SCV

Large momentary fluctuations in No. 1 cylinder speed. Large momentary fluctuations in No. 5 cylinder speed. Large momentary fluctuations in No. 3 cylinder speed. Large momentary fluctuations in No. 6 cylinder speed. Large momentary fluctuations in No. 2 cylinder speed. Large momentary fluctuations in No. 4 cylinder speed. Open circuit (external) in ECU terminal SCV+ or SCV-, GND short, or open circuit in SCV coil.

P1256 P1257 P1262 P1263 P1605 P1930

Output to SCV SCV Exhaust brake MV1 Exhaust brake MV1 ECU Power retarder relay

BATT short in ECU terminal SCV+ or SCV-. SCV seizure. Open circuit or GND short in the output to MV1. BATT short in the output to MV1. Malfunction in the flash memory. Open circuit, GND short or BATT short in the output to the retarder relay.

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