Engine Controller

ECM GST Nov 2005

Contents
Aim of development 3 Charge pressure and temperature sensors 25
Controller contour/connectors 4 Ambient pressure sensor 26
Power supply connector 4-pin (DTP06-4S) 6 Engine hydraulic switch 27
Engine connector 60-pin (DRC26-60S-05) 7 Water detector sensor (WIF) 28
Machine body connector 50-pin (DRC26-50S-04) 8 Coolant temperature sensor 29
Environment resistant specifications 9 Engine oil level sensor 30
SAABD107 and 114 engine control system 10 Sensor connectors 31
6D125, 140 and 170 engine control system 11
PC200-8 Testing, adjusting and troubleshooting
Table of sensors mounted on the engines 12
Measuring gear pump outlet port pressure 34
Engine control matrix 13
Measuring fuel leakage from pressure limiter 35
Machine-incorporated functions
14
(engine controller related) Measuring fuel return from injector 36
Basic flow of data (network) 16 Standard value for fuel return 37
Other functions 17 Removal and installation of injector 38
Service relations (function) 18 PC200-8 Monitoring Code List
39
(Engine relations)
Service and parts supply system 19
PC200-8 Error code list
Dynamo test 20 40
Engine relations
Engine Ne rotation sensor (crankshaft) 21
Troubleshooting of electrical system (E-42) 41
About top dead center TDC 22
Troubleshooting of electrical system (E-50) 43
Engine G rotation sensor (crankshaft) 23
PC200-8 Fuel system diagram 44
Common rail pressure sensor 24
ECM GST Nov 2005 Page 2 / 44
Aim of development
1. Development of common engines applicable to Komatsu's next
generation emission control compliance engine family
 Common ECM hardware applicable to engines from 3.3 to 78 liter piston
displacement
 Common ECM (for 107, 114, 125, 140, 170, 12V140, etc.) irrespective of
engine production plant
2. Development of communization between Komatsu and Cummins
brands
 Coexistence of production and service interfaces
 Sharing software development tool
3. Development of engine mount structure
 Improved engine production and service
4. Sharing hardware for mass production engines by Cummins
 Reduction of development and product costs
 From 10,000 units/year to the world of 100,000 units/year
 Development of mount technology for the Cummins engines currently in
mass production

ECM GST Nov 2005 Page 3 / 44

Controller contour/connector 1/2
52.7
CM870 / CM850 ASSEMBLY
4-4-00 100.2

280.4 52.7

226.1

24.8

Connector type No. Back shell type No.

Power supply harness DTP06-4S New setting required
Engine harness DRC26-60S-05 0528-002-6005
Machine body harness DRC26-50S-04 0528-001-5005
ECM GST Nov 2005 Page 4 / 44
 Controller contour/connector 2/2
50-pin machine body
4-pin power 60-pin engine
supply

107 engine controller mounting bracket

(Protection from the heat by thermal insulation effect)

ECM : Electronic Control Module

ECM GST Nov 2005 Page 5 / 44

Power supply connector 4-pin (DTP06-4S)

1 Battery power supply (-)

2 Battery power supply (-)

3 Battery power supply (+)

4 Battery power supply (+)

4-pin power
supply

60-pin
engine
50-pin
machine
body

ECM GST Nov 2005 Page 6 / 44

Engine connector 60-pin (DRC26-60S-05)
Pin No.1

Pin No.60

4-pin power
supply

60-pin
engine
50-pin
machine
body

ECM GST Nov 2005 Page 7 / 44

Machine body connector 50-pin (DRC26-50S-
04)
Pin No.1
Pin No.50

4-pin power
supply

60-pin
engine
50-pin
machine
body

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Environment resistant specifications
● <Principal environment resistant items>
● Actuating temperature: Ambient -40 to +105C

Vertical

Horizontal
Front-rear

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SAA6D107 and 114 engine control system
Service connector Key switch
* Dark current prevention: Prevents
Engine speed and position
Idle validation SW1
ECM current consumption and self-
Main pulse
Idle validation SW2 discharge of battery
Backup pulse
Throttle (fuel dial)
Injection control
Power train relay

Fuel feed pump (117 Eng only)

Injector #1
Injector #2
Injector #3 Communications via KOMNET
Injector #4 Transmitted to engine controller
Injector #5 1. LSI control
Injector #6 2. HSI control
Machine monitor 3. AS control
Fuel rail pressure Engine (panel) Throttle command
controller Throttle limit
Machine controller
Emission control #1 (pump controller) Throttle adjustment
Charge pressure 4. Power mode selection
Machine controller #2
Charge temperature (example: transmission 5. Cylinder cut-out
Ambient pressure controller)
No-injection cranking
Theft prevention

Engine monitor
Oil pressure switch Received from engine controller
Coolant temperature Power supply 1 (+) 1. Engine operation information
Power supply 2 (+) speed and output torque
Power supply 1 (-) 2. Error code
WIF (Water detection) Power supply 2 (-) 3. Monitoring information

ECM GST Nov 2005 Page 10 / 44

6D125, 140 and 170 engine control system
Service connector Key switch
Engine speed and position
Main pulse Idle validation SW1
Backup pulse Idle validation SW2
Throttle (fuel dial)
Injection control
Supply pump #1
Supply pump #2 Inlet heater sub-relay
Injector #1
Injector #2
Injector #3
Injector #4
Injector #5 Communications via
Injector #6 KOMNET
Transmitted to engine
Fuel rail pressure controller
Fuel temperature Machine monitor 1. LSI control
(panel)
Emission control 2. HSI control
Machine controller #1
EGR valve control (example: transmission 3. AS control
Bypass valve control controller)
Throttle command
Charge pressure Machine controller #2 Throttle limit
Charge temperature (example: brake controller)
Throttle adjustment
EGR valve inlet port pressure
4. Power mode selection

EGR valve lift control 5. Cylinder cut-out

Bypass valve lift control No-injection cranking
Ambient pressure Power supply 1 (+) Theft prevention
Ambient temperature Power supply 2 (+)
Engine monitor Power supply 1 (-)
Received from engine controller
Oil pressure sensor Power supply 2 (-)
1.Engine operation information
Coolant temperature
(optional) speed and output torque
Oil temperature
2. Error code
Exhaust temperature #1 3. Monitoring information
Exhaust temperature #2
Blow-by

ECM GST Nov 2005 Page 11 / 44

Table of sensors mounted on the engines
3. Table of sensors mounted on the tertiary emission control compliance engines
Sensor name

Ne rotation sensor (main)

G rotation sensor (backup)

Rail pressure sensor

Ambient pressure sensor

Charge pressure sensor

Exhaust gas pressure sensor

Hydraulic oil pressure sensor

Hydraulic SW

Intake temperature sensor

Charge temperature sensor

Coolant temperature sensor

Fuel temperature sensor

Oil temperature sensor

EGR valve lift

Bypass valve lift

Water detector sensor (WIF)

*1 Integrated charge pressure and

temperature sensor
ECM GST Nov 2005 Page 12 / 44
Engine control matrix
Tertiary emission Secondary Secondary
Tertiary emission control
Engine control matrix control emission control emission control

Hydraulic pressure (SW)

Hydraulic pressure (SW)

Ambient pressure

Ambient pressure

Exhaust pressure

Ambient pressure
Charge temperature
Charge temperature

Fuel temperature
Fuel temperature
Charge pressure

Charge pressure

Charge pressure

Charge pressure

Charge pressure
Intake air temperature

Hydraulic pressure
Hydraulic pressure
Coolant temperature

Coolant temperature
Coolant temperature

Coolant temperature
Control function
Injection capacity
Starting Main
Injection timing
injection
Injection pressure
Pilot injection Injection capacity (Split injection)
Injection intervals
Post injection Injection capacity
Injection intervals
Automatic warming-up Li revolution control
Turbo protection Accelerator position
Normal operation control
Main injection Injection capacity (Full Q only)
Cold time Injection timing
Injection pressure

Pilot injection Injection capacity

Injection intervals

Post injection Injection capacity

Injection intervals
Transition time Main injection Injection capacity (Charge control Q)
Injection timing
Injection pressure
Automatic high Main injection Injection capacity (V140 only)
altitude correction Injection timing (V140 only)
Injection pressure (V140 only)
EGR/EP valve Cold closing control
Transition time control
BP reverse prevention (bypass
Inlet heater control valve)
Relay drive

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Machine-incorporated functions 1/2
(engine controller related)
KOMNET-
Function Outline related
functions PC BL WA HD/HM
1. Accelerator
/ fuel dial interface
(1) Recognition of position signal Recognizes the pedal and/or dial -
for accelerator pedal, fuel dial, Fuel dial Desel pedal Accelerator pedal Accelerator pedal
and decel pedal position according to the voltage
(2) Zero-point learning function Learns the pedal idle position to correct -
pedal dispersion.
(3) Idle validation Redundant function for judging the pedal -
state with ON-OFF signal.
2. Output/Revolution control function
(1) Throttle correction Applies +/- correction to the accelerator
(For controlling hydraulic (throttle dial) ) (Transmission (Transmission
position according to KOMNET command. driven fan engine output for
PC600 or higher) interlock control) interlock control)

(2) Torque control Controls torque with equal horsepower

(For controlling hydraulic
(partial performance) control (mid range governor) through driven fan engine output (For controlling
accelerator position for PC600 or higher) engine output for
(3) Regulation control 2 Max. rpm control. Controls HIS governor D155 only)
(For controlling hydraulic (For controlling
(partial performance) break point rpm according to KOMNET driven fan engine output
command engine output for
for PC600 or higher)
D155 only)
(4) Throttle upper limit Controls higher value of accelerator position
according to KOMNET command. For Auto-Decel control For Auto-Decel
control control
(5) Throttle lower limit Controls lower value of accelerator position
control according to KOMNET command. (Li up, (Li up,
accelerator lock) accelerator lock)
(6) Governor mode Selects all speed or mid range governor
selection (For controlling engine
output for D155 only)
(7) Power mode selection Selects power curve according to
KOMNET command 4 mode
(8) Regulation control All speed control (selects combination of
(partial performance) droop SW/ABS and HSI) (All speed/PC500 or (All speed/PC600 or (All speed) (Mid range))
3 mode higher mid range) higher mid range)

(9) Li selection (automatic To reduce cold warming-up time, functions are

provided for selecting Li according to the coolant
warming-up)
temperature, time, and cancellation with KOMNET)

ECM GST Nov 2005 Page 14 / 44

Machine-incorporated functions 2/2
(engine controller related)
KOMNET-
Function Outline related
functions PC BL WA HD/HM
3. Protection/Compensation function
(1) Automatic To improve cold startability, grid heater is driven for
preheating/post heating a set time depending on the water/intake air
temperature. Preheating displayed on the indicator
(Auto preheat)
(2) Output rpm derate Controls engine output/rpm at the time of -
a failure
(3) Turbo protection To protect turbo during engine start, throttle is controlled for -
a set time depending on the hydraulic pressure rise and
coolant temperature.
(4) Fuel temperature correction Corrects fuel injection capacity according to the spill -
fuel temperature (not with B and C engines)

(5) Automatic high altitude To protect engine, engine output, injection timing -
and injection pressure are controlled depending on
compensation the Ambient condition.
4. Communication/Troubleshooting function
(1) KOM-NET/c communication Receives commands via KOMNET and
(monitoring) transmits sensor signals and internal signals.
(2) Self-diagnosis Detects and takes measures for a failure, simultaneously
transmitting error code with J1939. Error code is converted
(error code indication) to a 6-digit code for display on the panel
(3) Caution indication Hydraulic pressure drop, overheat, and WIF

(4) Cylinder cut-off function To discriminate a failing injector from the

panel, a random selected cylinder can be
stopped.are stopped from
Injection of all cylinders
(5) No-injection cranking
the panel.
(6) Theft prevention Step2 Engine start enabled from the panel by
checking password (PC200,)
5. Machine management
(1) Measures for preventing Dark current is eliminated by turning the rely, -
buttery consumption while the
key is OFF inserted to the power line, OFF (PC300 or under)
(2) VHMS Transmits error code and engine information
on demand via KOMNET
(3) KOMTRAX Transmits error code and engine information
on demand via KOMNET

ECM GST Nov 2005 Page 15 / 44

Basic flow of data (network)
Medium to small type hydraulic excavators

Monitor Engine controller Pump controller

Unicast RTCDB
 Transmission of error code
 Fast processing speed
 Serves as the master controller

Large type hydraulic excavator

Monitor Engine controller Engine controller Pump controller 1 Pump controller 2

Unicast RTCDB

ECM GST Nov 2005 Page 16 / 44

Other functions

 Automatic high altitude compensation function

 Incorporated with automatic high altitude compensation function
currently on production with 170 engines (standard coverage up
to 2,300 m)
 Fuel injection is derated according to application (rating) from
where the machine exceeds an altitude reachable without
derating
 Ambient pressure sensor is engine-mounted
 Default starting function
 Engine can start even if the coolant sensor, engine hydraulic
pressure switch, etc. has an error (example: by making judgment
that the coolant temperature is at 90C and the hydraulic switch
being normal as default)

ECM GST Nov 2005 Page 17 / 44

Service relations (function)

1).Troubleshooting and data monitoring from machine

monitor panel
6-digit error code, monitoring function (via KOMNET)
2).Operation in reduced cylinder mode
Operation is enabled from the monitor panel via KOMNET.
3).No-injection cranking function
Operation is enabled from the monitor panel via KOMNET.
4).Dynamo test
Cummins dynamo tool of INSITE is used (common with
downloader tool)

ECM GST Nov 2005 Page 18 / 44

Service and parts supply system

1. Controller supply and writing are covered by

replacing assembly (plant is responsible for the writing)
 Similar with the current CRI controller for 125 and 140 or
CM500 for 170 engines, white controller ECM and software
are separately supplied
 Cummins software is used for writing software

2. Repair of controllers
 Repairing of controller (CM850) is disabled since it is
designed and manufactured with bending structure of
integrated flexible substrate and casing for achieving
lightweight, high product quality and low cost

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Dynamo test

Writing and output adjustment are disabled

Next generation emission control Secondary emission control (125 and 140)
Engine Engine

ECM

Throttle box Throttle box ECM

PC

Battery Battery
PC
(Identical configuration (Download)
with the current 170)

ECM GST Nov 2005 Page 20 / 44

Engine Ne rotation sensor (crankshaft)

Major functions
 Senses the top dead center of cylinders
No. 1 to 6 of the engine
 Applies the Hall element effect

Rotating ring TDC sensory notch

Ne rotation
sensor
ECM GST Nov 2005 Page 21 / 44
About top dead center TDC
Directly
overhead
position

72 degrees to
the left

Position with TDC stamping and a

groove (on the circumference of the
damper)

1 to 6 reaches TDC when this groove and

Notch on the rotating ring stamped TDC are at position (P) overhead
matches Ne sensor
Rotate the position in the photo to the left 72
degrees to the right to attain TDC for 1 to 6

ECM GST Nov 2005 Page 22 / 44

Engine G rotation sensor (crankshaft)

Six (6) plus 1 grooves are

cut to the end of camshaft
Major functions
Senses a combusting cylinder
Applies the Hall element effect
G rotation sensor

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Common rail pressure sensor

Major functions
Common rail internal pressure control

Common rail pressure sensor

ECM GST Nov 2005 Page 24 / 44

Charge pressure and temperature sensors

Major functions
Determining fuel for injection
Intake air preheating control

Charge pressure and

temperature sensors
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Ambient pressure sensor

Major functions
Automatic altitude compensation and
fuel injection

Ambient
pressure sensor

ECM GST Nov 2005 Page 26 / 44

Engine hydraulic switch

Major functions
Warning to hydraulic pressure drop
Protection of turbocharger

Hydraulic switch

ECM GST Nov 2005 Page 27 / 44

Water detector sensor (WIF)

Major functions
Senses water level in the fuel prefilter
Warns high or low water level

Water-presence sensor

ECM GST Nov 2005 Page 28 / 44

Engine coolant temperature sensor

Control functions
Monitors temperature and warns overheating
Determining fuel for injection
Automatic warming-up
Protection of turbocharger

Coolant temperature sensor

ECM GST Nov 2005 Page 29 / 44

Engine oil level sensor

Warning to abnormally low engine oil

level

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Sensor connectors 1/2

1.In locked condition 2.Sliding the lock 3. Withdraw the lock by

pressing the knob

3-pin harness connector

ECM GST Nov 2005 Page 31 / 44
Sensor connectors 2/2

Connector with lock,

charge sensor, etc.

ECM GST Nov 2005 Page 32 / 44

 PC200-8 Testing, adjusting and
troubleshooting

ECM GST Nov 2005

Measuring gear pump outlet port pressure

Engine in low idle revolution

Standard value: 5.1 kg/cm2 to 13.3 kg/cm2

Low
At cranking time
pressure (when starting disabled)
fuel circuit At low idling time
pressure
(when starting enabled)

ECM GST Nov 2005 Page 34 / 44

Measuring fuel leakage from pressure limiter
(2) Injector return
Measure leakage as a means for judging
pressure limiter performance
No leakage if normal Fuel cooler Tank
return connection

(1) Leak from

Pressure limiter pressure
limiter (3) Supply pump drain

Leakage
outlet port

ECM GST Nov 2005 Page 35 / 44

Measuring fuel return from injector
Measure the return capacity as a means
for determining the injector performance (2) Injector return

Fuel cooler Tank

(2) return connection

(1) Leak from

(3) pressure
limiter (3) Supply pump drain

Reference value for measured return capacity: Engine Swing lock or arm relief time/30 sec.
in low idling/30 sec (2) Injector: 90 cc (3) Pump: 440 cc
(2) Injector: 40 cc (3) Pump: 400 cc
ECM GST Nov 2005 Page 36 / 44
Standard value for fuel return

Estimated causes of leakage and standard value

under normal condition
For checking leak from the pressure limiter, see the "Checking
on fuel return and leakage" in Checking and Adjusting section.
Defective pressure
limiter Pressure limiter At low idling time 0 cc (no leakage)
leakage
For checking leak capacity from the injector, see the "Checking on
fuel return and leakage" in Checking and Adjusting section.
Defective pressure
(including high At cranking time (when
pressure piping starting disabled)
Injector return
inside the head) capacity At low idling time
(when starting
enabled) Measuring return
For checking return capacity from the supply pump, see the "Checking
on fuel return and leakage" in Checking and Adjusting section.
capacity from injector
Defective At cranking time (when
supply pump Return capacity starting disabled)
from supply pump
At low idling time (when
starting enabled)

ECM GST Nov 2005

Removal and installation of injector
1. Apply engine oil to the O-ring on the injector and the
portion inserted to the head
(4) (3)
2. Temporarily install holder (2) to the injector, install
them in that state to the head tentatively, manually
fasten bolt (1) to attach to holder (2)
3. Tighten bolt (1) finely and alternately to press-fit the
injector and tighten by applying 10 Nm (10 Nm > torque
(1) for temporary tightening)
(2)
4. Insert connection (3) and tighten with nut (4) with 15
Nm (apply oil to O-ring)
5. Loosen bolt (1) again
6. Tighten bolt (1) with 10 Nm.
7. Tighten connection nut (4) with 50 Nm

Removal and
installation of injector
ECM GST Nov 2005
PC200-8 Monitoring Code List (Engine relations)
Name of
component to
Monitoring ID Monitoring display item name become the Unit
CM ENG
data server 850 (CRI)
00201 Machine ID ENG --
01002 Engine Speed ENG rpm
04107 Coolant Temperature ENG C
03203 Battery Power Supply ENG mV
36400 Rail Pressure ENG MPa
37400 Ambient Pressure ENG MPa
18400 Intake Temperature ENG C
18500 Charge Temperature ENG C
36700 Engine Torque Ratio ENG %
18700 Engine Output Torque ENG Nm
03000 Fuel Dial Pos Sens Volt ENG mV
04105 Eng. Water Temp. Vol. Lo ENG mV
37401 Ambient Press Sens Volt ENG mV
18401 Intake Temp Sens Volt ENG mV
18501 Charge Temp Sens Volt ENG mV
36501 Charge Press Sens Volt ENG mV
36401 Rail Pressure Sens Volt ENG mV
17500 Engine Power Mode ENG --
31701 Throttle Position ENG %
31706 Final Throttle Position ENG %
18600 Inject Fueling Command ENG mg/st
36200 Rail Press Command ENG MPa
36300 Injection Timing Command ENG CA
37300 Fuel Rate ENG L/h
04501 Monitor Input 2 MON
Aircleaner MON
Eng. Oil Level MON
Battery Charge MON
18800 Water In Fuel ENG
20216 Build Version ENG --
20217 Calibration Data Ver ENG --
18900 ECM Internal Temp ENG C
20400 ECM S/N ENG --

ECM GST Nov 2005

PC200-8 Error Code List (Engine relations)
6 figure code Name by the monitor User code 6 figure code Name by the monitor User code

CA111 Engine controller internal abnormality E10 CA322 Injector #1 disconnection, short circuit abnormal E11
CA115 Engine Bkup rotation sensor abnormal E10 CA323 Injector #5 disconnection, short circuit abnormal E11
CA122 Charge pressure sensor abnormally high E11 CA324 Injector #3 disconnection, short circuit abnormal E11
CA123 Charging pressure sensor abnormally low E11 CA325 Injector #6 disconnection, short circuit abnormal E11
CA131 Throttle sensor abnormally high E14 CA331 Injector #2 disconnection, short circuit abnormal E11
CA132 Throttle sensor abnormally low E14 CA332 Injector #4 disconnection, short circuit abnormal E11
CA144 Water temperature sensor abnormally high E15 CA342 Engine controller data matching abnormal E10
CA145 Coolant temperature sensor abnormally low E15 CA351 Injector drive circuit abnormal E10
CA153 Charging temperature sensor abnormally high E15 CA352 Sensor power supply 1 abnormally low E15
CA154 Charging temperature sensor abnormally low E15 CA386 Sensor power supply 1 abnormally high E15
CA155 Charge temperature abnormally high rotation derate E11 CA428 Water detector sensor abnormally high E15
CA1633 KOMNET abnormal E0E CA429 Water detector sensor abnormally low E15
CA187 Sensor power supply 2 abnormally low E15 CA435 Engine oil pressure switch abnormal E15
CA2185 Throttle sensor power supply abnormally high E14 CA441 Supply voltage abnormally low E10
Error of electrical system (engine)

Error of electrical system (engine)

CA2186 Throttle sensor power supply abnormally low E14 CA442 Supply voltage abnormally high E10
CA221 Ambient pressure sensor abnormally high E11 CA449 Common rail pressure high abnormal 2 E11
CA222 Ambient pressure sensor abnormally low E11 CA451 Common rail pressure sensor abnormally high E11
CA2249 Supply pump no feed abnormality 2 E11 CA452 Common rail pressure sensor abnormally low E11
CA227 Sensor power supply 2 abnormally high E15 CA488 Charge temperature abnormally high torque derate E11
CA2311 IMV solenoid abnormal E11 CA553 Common rail pressure high abnormal 1 E15
CA238 Ne rotation sensor power supply abnormal E15 CA559 Supply pump no feed abnormality 1 E15
CA2555 Inlet heater relay disconnection abnormal E15 CA689 Engine Ne rotation sensor abnormal E15
CA2556 Inlet heater relay short circuit abnormal E15 CA731 Engine Bkup rotation sensor phase abnormal E15
CA271 IMV short circuit abnormal E10 CA757 Engine controller total data loss abnormality E10
CA272 IMV disconnection abnormal E10 CA778 Engine Bkup rotation sensor abnormal E15

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 Troubleshooting of electrical system (E-42) 1/2

E-42 code [559/CA559] supply pump no feed abnormality 1

Error code Failure code Faulty

phenomenon Supply pump no feed abnormality 1

Content of failure • No feed abnormality (1) generated to common rail circuit

Action by • No particular action

controller
Phenomenon • Engine not starting or poor startability
appearing on • Exhaust color is blackish
machine • Engine output drops

Related
• Reproduction method of a failure code: Start engine
information

Remarks: Error is output if a state of minus (-) 100 bar to target

pressure value persists for 5 seconds

ECM GST Nov 2005

 Troubleshooting of electrical system (E-42) 2/2

Cause Normal standard value and remarks for diagnosis

Direct visual check (with engine at low idling) for possible
External leakage of fuel
external leakage of fuel
For checking low-pressure fuel circuit pressure, see the "Checking
on fuel pressure" in Checking and Adjusting section.

Defective low-pressure At cranking time (when

Low pressure starting disabled)
circuit equipment fuel circuit
At low idling time (when
pressure starting enabled)

For checking leak from the pressure limiter, see the "Checking on
fuel return and leakage" in Checking and Adjusting section.
Estimated Defective pressure limiter
causes of Pressure limiter
At low idling time 0 cc (no leakage)
troubles and leakage
standard For checking a return capacity from the injector, see the "Checking
value under on fuel return and leakage" in Checking and Adjusting section.
normal
condition
Defective pressure At cranking time (when
(including high pressure Injector return starting disabled)
piping inside the head) capacity At low idling time (when
starting enabled)

 For checking return capacity from the supply pump, see the "Checking on
fuel return and leakage" in Checking and Adjusting section.

At cranking time (when

Defective supply pump Return capacity starting disabled)
from supply
At low idling time (when
pump starting enabled)

ECM GST Nov 2005

 Troubleshooting of electrical system (E-50)

E-50 code [2249/CA2249] supply pump no feed abnormality 2

Error code Failure code Faulty

phenomenon Supply pump no feed abnormality 2

Content of failure • No feed abnormality (1) generated to common rail circuit

Action by
controller •Operates by controlling output

Phenomenon • Poor engine startability

appearing on • Exhaust color is blackish
machine • Engine output drops
Related
•Reproduction method of a failure code: Start engine
information

Estimated causes
of troubles and
Cause Normal standard value and remarks for diagnosis
standard value
under normal Implement troubleshooting for failure code [CA559]
condition

Remarks: Error is indicated via the following two processes:

1. After the state of minus (-) 100 bar to the target pressure value persisted for 5 seconds,
2. A state of minus (-) 150 bar to the target pressure value persists for 20 seconds

ECM GST Nov 2005

 PC200-8 Fuel system diagram

Pressure limiter

Common rail

* Return
check
Overflow valve
valve
Injector

Priming pump
Main filter

Fuel cooler
IMV valve
Gear pump
Supply pump Prefilter
Fuel tank

(1) Pressure limiter 1,850 bar (4) Return Check valve 0.48 bar * Zero-delivery choke (: dia. 0.4mm) Even if the valve
closes, little amount of fuel flows to the supply pump
plunger, this fuel is directed to the returning side via the
(2) Relief valve 105 bar to 13 bar (3) Bypass valve 0.1 bar choke to retain the state of zero-delivery
Normally no fuel flows

ECM GST Nov 2005