Mitsubishi Fuso Fighter 2004 User Manual

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 1-1. Outline

• This manual describes the common rail system installed in the 6M60 engine of the Mitsubishi Fuso Fighter. The most
significant diffe rence to the c onventiona l common rai l system is that thi s system employs a c ompact an d lightweigh t HP4
supply pump, and a G2 injector with bet ter response. For more details on the common rail system, refer to se rvice manual
No. 00400041 "Common Rail System for HINO J05D/J08E Type Engine", issued in October 2003.

-1-

2. PRODUCT APPLICATION LIST 2-1. Vehicle Specifications

Vehicle Name Engine Model Engine Displacem en t Remarks

Mitsubishi Fuso Fighter 6M60 7,545 cc

2-2. Component Part N umbers

Part Name DENSO P/N Mitsubishi P/N Remarks

Injector 095000-5450 ME302143
Rail 095440-0570 ME302292
Flow Damper ME743861 Rail Component Parts
Pressure Limiter ME743862
Pc sensor ME743864
Supply Pump 294050-0050 ME302145 12V Specification
ECU 275800-3401 ME302751 6M60T1

275800-3411 ME302752 6M60T2

275800-3451 ME302986 6M60T1 (Allison AT)
Boost Pressure Sensor 079800-5580 MK369080
TDC (MRE) Sensor 949979- 142 0 ME301026
NE (MPU) Sensor 029600-0570 MC885578
Intake Air Temperature

Sensor
Fuel Temperature Sensor 179730-0030 MC885579
Accelerator Position Sensor 198300-7030 ME162376

071500-2571 ME352426

-2-

3. GENERAL DESCRIPTION OF MAIN NEW FEATURES 3-1. Common Rail Specifications and Engine Elements

FK6

Common Rail Specifications Main Elements HP-4 + G2

Pressure Used 170MPa

Engine Elements Model L6, TI, 4 valves.

Engine Displacement 7.5L
Output 199kW/2700rpm
Torque 785N•m/1400rpm

3-2. System Configuration

A. Overall System

Pressure limiter

Engine ECU

Fuel temperature
sensor

Rail

Supply pump

Rail pressure sensor

Injector

Filter

Fuel tank

SCV
(Suction Control Valve)

-3-

Q000660E

4. MAIN FUNCTIONAL PARTS 4-1. Changes to the Main Functional Pa rts

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

4-2. Supply Pump

A. Changes

Significant changes are listed below.

Model HP-4

Rotation Ratio Np : Ne 1 : 1

Maximum Speed 4000rpm

Direction of Rotation Counter clockwise (viewed from actuating side).

Component Parts Feed Pump Trochoid Type

SCV Rated Voltage 12V

Type Normally Open

Plunger Diameter × No. ϕ8.5 × 3

Lift Amount 8.8mm

Fuel Temperature Sensor 2.45 ± 0.24kΩ (20°C)

B. External View

SCV

Fuel temperature sensor

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

Q000662E

-4-

Plunger

Ring cam

Q000663E

• 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

4-3. Rail

A. External View

Plunger #3

Plunger #3 Highest Point

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

Pressure limiter

Eccentric
cam

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

Plunger #2 Highest Point

Rail pressure sensor

Ring
cam

Q000664E

to Injector

Flow limiter

High-pressure fuel inlet

to Fuel tank

to Injector

Q000665E

-5-

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.

V

OUT

Atmospheric temperature: 25°C

VC=5V

4.2

3.6

2.6

1.3

VC VOUT GND

1.0
0

0 20 100

160

200

Rail pressure (MPa)

C. Flow Limiter

A flow limiter is employed ins tea d of a flow damper. As with the fl ow da mpe r , the flo w lim ite r close s th e fue l pa ss age to
prevent further flow of fuel in the event of an exces sive fuel flow. If an abnormal flow occu rs, the high pr essure forces the
piston up. This closes the fuel passage leading to the seat.

to Injector

Body

Q000666E

Spring

Piston

Stopper

D. Pressure Limiter

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

·Open valve pressure: 221±9MPa

Housing

Valve guide

Valv e

Rail side

Q000667E

Spring

Valve body

Q000668E

-6-

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)

Command piston

Nozzle spring

Pressure pin

Nozzle needle

Control chamber

Seat

High-pressure fuel

Leak passage

Q000669E

-7-

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 initial ly applie d to the so lenoid, the attraction of the sol enoid pul ls the TWV (s olenoid v alve) up, ope ning
the outlet orifice and allow ing fuel to flow out of the contro l chamber. After the fuel fl ows 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 s olenoid, the no zzle reaches its maximum lift , where the injecti on rate is also
at the maximum leve l. When c urrent to the soleno id is turn ed OFF, the TWV (solen oid val ve) fall s and cl ose s the orif ice.
Fuel then flows i nto the co ntrol chamber via th e i nle t o rifi ce, increasing pressure an d c au sin g t he noz zl e needle to close
immediately and injection to stop.

Solenoid

TWV

Outlet orifice

Inlet orifice

Command piston

Nozzle

Non-injection

Actuating
current

Rail

Control
chamber
pressure

Injection rate

Injection

Actuating
current

Control
chamber
pressure

Injection rate

Actuating
current

Control
chamber
pressure

Injection rate

Injection ends

QD0717E

-8-

4-5. Sensor Additi ons and Changes

A. Cylinder Recognition Sensor (TD C Sensor)

• The cylinder recognition sensor is an MRE (Magneto Resistive Element) type. As the teeth in the cylinder recognition
sensor pass the se nsor, the magneti c resist ance in the se nsor change s. The change in the v oltage g enerated i s conve rt­ed into a rectangular wave pul se in the IC circuit, and this sig nal is output to the engine ECU. A cylin der recognition pulsar
is installed to the engine camshaft gear, and it outputs the cylinder recognition signal.

TDC (cylinder recognition)
sensor

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

Q000680E

NE+
(NE-reference)

G (TDC signal)
(G-reference)

0°CA 120°CA 240°CA 360°CA 480°CA 600°CA 720°CA

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

78°CA 78°CA 78°CA 78°CA 78°CA 78°CA

#5TDC

#3TDC

4 missing
teeth

#6TDC

3°CA

#2TDC

Extra tooth

#4TDC

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

30°CA

No.1 reference pulse

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 (kΩ)

(25.4)

15.0±1.5
(9.16)
(5.74)
(3.70)

2.45±0.24(R

O)

(1.66)
(1.15)

(0.811)
(0.584)
(0.428)

0.318±0.031
(0.240)

(0.1836)
(0.1417)

(0.1108)

#1TDC

Q000671E

Q000672E

-9-

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. Simila r to the other temp erature sensors, it uses a thermisto r. The tempera ture versus resi stance ch ar­acteristics are shown in the diagram below.

[Temperature - Resistance Characteristics]

Intake air temperature
sensor

Temperature (°C)

(-30)

(-20)

-10

20

80

(120)

Resistance Value (kΩ)

(26.758)

(16.2)

5.88±0.588

2.45±0.245

0.322±0.0483

(0.1058)

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 applie d to silicon crystal. Th e intake air pressure sen sor is used to correct the ful l load injection qua ntity
data programmed in the engine ECU. The relationship between pressure and output voltage is shown in the diagram
below.

Q000673E

Intake air pressure sensor

[Pressure Characteristics]

Output voltage (V)

4.500

3.220

GND

P

B

V

C

0.500

66.67

202.67

Intake air pressure (kPa)

VC=5V

266.67

Q000674E

-10-

5. CONTROL OPERATION CHANGES 5-1. Idle-Up

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

A/C switch: ON

Vehicle speed: 0km/h

Neutral switch: ON

Q000677E

-11-

6. ECU RELATED 6-1. External Wiring Diagram

*1: For the 6M60T1 engine.

Starter
switch

Meter

15A

5A

5A

ISS engine
starter relay

ISS

Starter continuous
energization prevention
relay

to Starter relay

ABS/ASR
ECU

+5V

SIG

GND

Accelerator position
sensor 1

Accelerator position
sensor 2

Accelerator SW

AT recognition SW

Frame ground

Diagnosis SW

120Ω

Fuse

Main fuse

Battery 12V

Cylinder recognition sensor

ISS ECU

20A

Fuse

Vehicle
control ECU

ECU main relay

TWV1 (#1 cylinder)

TWV3 (#3 cylinder)

TWV5 (#2 cylinder)

TWV2 (#5 cylinder)

TWV4 (#6 cylinder)

TWV6 (#4 cylinder)

Engine speed
sensor

Diagnosis memory clear SW

Rail pressure sensor 1

Rail pressure sensor 2

MUT-3
(KWP2000)

Coolant temperature sensor

Fuel temperature sensor

Intake air temperature sensor

EGR MV1

EGR MV2

EGR MV3

46

56

ECU

48

43

157

158

35

76

74

75

5

6

7

102

140

73

141

72

18

106

107

103

104

105

142

143

137

138

139

40

41

39

133

120

131

126

21

134

123

22

136

61

108

109

110

77

67

125
121

132

135

19

68

55

155

162

154

52

58

59

111

85

79

80

82

83

84

70

27

53

Dual pressure SW

97

9

11

51

10

66

31

26

57

54

128

30

62

8

163

146

147

144

145

Pilot light

Exhaust brake MV1

Exhaust brake lamp

Glow relay

Pulse divider

R

D

2

L

Gear position SW

Clutch SW

Neutral SW

Warm-up SW

Exhaust brake SW

Diagnosis light 1

Diagnosis light 2

Glow light

Glow relay
Actuation relay

Glow plug

Magnetic clutch relay

Exhaust brake cut SW

+12V

GND

Air conditioning SW
10A

Torque cut SW

AT ECU

Development output

PTO accelerator position sensor

N correction resistor

Boost sensor

IMC volume

Quantity correction resistor

Tachometer

HP-4. Injection pump

Fuel temperature
sensor

SCV

ABS assist
brake cut relay

Vehicles not equipped
with ABS

A/T
ECU

Vehicle speed sensor

NE OUT

PWM accelerator

Idle-up cancel SW

Meter cluster

ABS
ECU

(For transmission PTO)

(For flywheel PTO)

PTO relay

PTO SW
pilot light

MV (transmission)

PTO SW

-12-

Q000681E

6-2. Terminal Layout

6-3. Terminal Symbol Explanation

A. Terminals No. 1 to 34

Q000679E

No.

Terminal

Name

1 - - 18 CASEGND Case ground
2 - - 19 KWP2000 MUT-3
3- - 20- ­4 - - 21 AD1 Accelerator position sensor 1
5 +B +VB 22 AD2 Accelerator position se nsor 2
6+B +VB 23 - ­7+B +VB 24 - ­8 TAC1 Tachometer signal 25 AD19 Temperature sensor 4 for after-treat-

9 TAC2 NE OUT 26 AD20 N correction resistor
10 POUT1 Development output (Q-OUT) 27 VS1 Vehicle speed sensor
11 POUT2 PWMACC 28 - ­12 - - 29 - ­13 - - 30 AD14 IMC volume
14 - - 31 AD15 PTO accelerator position sensor
15 - - 32 - -

Signal Name No.

Terminal

Name

Signal Name

ment (following EGR merging).

16 - - 33 - ­17 - - 34 - -

B. Terminals No. 35 to 69

No.

Terminal

Name

35 +BF SURGE OUT 1 53 SW7 Air conditioning switch
36 - - 54 A-GND4 Sensor GND4
37 - - 55 A-GND5 Sensor GND5
38 - - 56 SW1 Key switch
39 NE-SLD NE-SLD 57 A-VCC4 Sensor power supply 4
40 NE+ Engine speed sensor + 58 SW8 Neutral switch
41 NE- Engine speed sensor - 59 SW10 Warm-up switch
42 - - 60 - ­43 OUT2 Relay to prevent continuous starter

energization.

Signal Name No.

Terminal

Name

61 SW17 Accelerator swit ch

Signal Name

-13-

No.

Terminal

Name

44 - - 62 AD21 Quantity correction resistor
45 - - 63 - ­46 SW1 Key switch 64 - ­47 - - 65 - ­48 SW2 Starter switch 66 SW9 PTO switch
49 SW3 Exhaust brake switch 67 SW11 AT recognition switch
50 - - 68 SW16 Diagnosis switch
51 SW5 Idle-up cancel switch 69 - ­52 SW6 Clutch switch 1

Signal Name No.

Terminal

Name

Signal Name

C. Terminals No. 70 to 101

No.

Terminal

Name

70 OUT19 Glow relay actuation relay 86 - ­71 - - 87 - ­72 GND ECU analog GND 88 - ­73 GND ECU analog GND 89 - ­74 OUT17 ECU main relay 90 - ­75 OUT18 ECU main relay 91 - ­76 +BF SURGE OUT 2 92 - ­77 SW27 Diagnosis memory clear switch 93 - ­78 - - 94 - ­79 - - 95 - ­80 SW15 Exhaust brake cut switch 96 - ­81 - - 97 - ­82 S-OUT1 Diagnosis light 1 (red) 98 - ­83 S-OUT2 Diagnosis light 2 (orange) 99 - ­84 S-OUT3 Glow light 100 - ­85 S-OUT4 Exhaust brake light 101 - -

Signal Name No.

Terminal

Name

Signal Name

D. Terminals No. 102 to 136

No.

102 P-GND POWER GND 120 G G sensor +
103 TWV1 Injector drive signal 1 121 AD4 Rail pressure sensor 1
104 TWV3 Injector drive signal 3 122 - ­105 TWV5 Injector drive signal 5 123 A-VCC3 Sensor power supply 3
106
107
108 - - 126 A-VCC1 Sensor power supply 1
109 - - 127 - -

Terminal

Name

COMMON1
COMMON1

Signal Name No.

Injector drive power supply 1-1 124 - ­Injector drive power supply 1-2 125 A-VCC2 Sensor power supply 2

Terminal

Name

Signal Name

-14-

No.

110 - - 128 AD3 Boost sensor
111 OUT12 Exhaust brake MV1 129 - ­112 - - 130 - ­113 - - 131 G-GND G sensor
114 - - 132 AD5 Rail pressure sensor 2
115 - - 1 33 G-VCC CAM ANGLE VCC (5V)
116 - - 134 A-GND1 Sensor GND1
117 - - 135 A-GND2 Sensor GND2
118 - - 136 A-GND3 Sensor GND3
119 - -

Terminal

Name

Signal Name No.

Terminal

Name

Signal Name

E. Terminals No. 137 to 167

No.

137 TWV2 Injector drive signal 2 153 - ­138 TWV4 Injector drive signal 4 154 AD6 Intake air temperature sensor (before
139 TWV6 Injector drive signal 6 155 AD7 Coolant temperature sensor
140 P-GND POWER GND 156 - ­141 P-GND POWER GND 157 CAN1H CAN1 HIGH
142
143
144 SCVLO HP3 and HP4 suction control valve

145 SCVLO HP3 and HP4 suction control valve

146 SCVHI HP3 and HP4 suction control valve

147 SCVHI HP3 and HP4 suction control valve

148 - - 164 - -

Terminal

Name

COMMON2
COMMON2

Signal Name No.

Injector drive power supply 2-1 158 CAN1L CAN1 LOW
Injector drive power supply 2-2 159 - -

drive signal 1

drive signal 2

power supply 1

power supply 2

Terminal

Name

160 - -

161 - -

162 AD8 Fuel temperature sensor 1 (leak side)

163 AD9 Fuel temperature sensor 2

Signal Name

149 - - 165 - ­150 - - 166 - ­151 - - 167 - ­152 - -

-15-

7. DIAGNOSTIC TROUBLE CODES (DTC) 7-1. DIAGNOSTIC TROUBLE CODES LIST

DG Code Source Malfunction Outline

P0107 Atmospheric pressure sensor Output from the atmospheric pressure sensor is too low.
P0108 Atmospheric pressure sensor Output from the atmospheric pressure sensor is too high.
P0112 Intake air temperature sensor Output from the intake air temperature sensor is too low.
P0113 Intake air temperature sensor Output from the intake air temperature sensor is too high.
P0117 Coolant temperature sensor Output from the coolant temperature sensor is too low.
P0118 Coolant temperature sensor Output from the coolant temperature sensor is too high.
P0121 Accelerator position sensor
P0122 Accelerator position sensor No. 1 Output from the accelerator position sensor is too low.
P0123 Accelerator position sensor No. 1 Output from the accelerator position sensor is too high.
P0187 Fuel temperature sensor Output from the fuel temperature sensor is too low.
P0188 Fuel temperature sensor Output from the fuel temperature sensor is too high.
P0191 Rail pressure sensor Output from the rail pressure sensor is fixed at a middle value.
P0192 Rail pressure sensor Output from the rail pressure sensor is too low.
P0193 Rail pressure sensor Output from the rail pressure sensor is too high.

Output from accelerator position sensors No. 1 and No. 2 is inconsistent.

P0200 Injector COM1 COM1 is open or s hort ci rcuited ; or TWV1, TM V3 or TWV5 is open or

short circuited.
P0201 Injector TWV Open circuit in the TWV1 wiring or injector coil.
P0202 Injector TWV Open circuit in the TWV5 wiring or injector coil.
P0203 Injector TWV Open circuit in the TWV3 wiring or injector coil.
P0204 Injector TWV Open circuit in the TWV6 wiring or injector coil.
P0205 Injector TWV Open circuit in the TWV2 wiring or injector coil.
P0206 Injector TWV Open circuit in the TWV4 wiring or injector coil.
P0219 Overrun Engine is overrunning.
P0222 Accelerator position sensor No. 2 Output from the accelerator position sensor is too low.
P0223 Accelerator position sensor No. 2 Output from the accelerator position sensor is too high.
P0227 PTO accelerator position sensor Output from the PTO accelerator position sensor is too low.
P0228 PTO accelerator position sensor Output from the PTO accelerator position sensor is too high.
P0234 Abnormally boost pressure Boost pressure is excessive or insufficient.
P0237 Intake air pressure sensor Output from the intake air pressure sensor is too low.
P0238 Intake air pressure sensor Output from the intake air pressure sensor is too high.
P0251 Fuel leak Fuel leak in the injection system or fuel system.
P0252 Pressure limiter Pressure limiter is operating.
P0253 Abnormally high pressure 2 Output from the rail pressure sensor is over the higher upper limit.
P0254 Abnormally high pressure 1 Output from the rail pressure sensor is over the lower upper limit.
P0255 Supply pump 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 Source Malfunction Outline

P0257 Supply pump Poor pumping in the supply pump No. 1 cylinder.
P0335 Engine speed sensor No signal output from the engine speed sensor.
P0340 TDC sensor No signal output from the TDC sensor.
P0380 Glow relay BATT short in the output to the glow relay. Open or GND short in the

glow relay output.
P0500 Vehicle speed se nsor Open or short circuit in the vehicle sp eed sens or; fr equ enc y is too

high; no output.
P0506 IMC volume IMC volume signal is too low.
P0507 IMC volume IMC volume signal is too high.
P0510 IDLE switch IDLE switch is seized closed.
P0600 SLD system Communication error between the vehicle speed control ECU and

engine ECU or vehicle speed sensor.
P0605 CPU (in the engine ECU) Main CPU malfunction or watchdog malfunction.
P0616 Starter prohibition relay BATT short in the output to the starter prohibition relay.
P0617 Starter prohi bition relay Open circui t (external) or GND short in the output to the starter prohi-

bition relay.
P1121 Intake throttle valve Open circuit, GND short or BATT short in the output to valve MV1.
P1171
P1172
P1176
P1177
P1185 Engine stop switch Engine stop switch is seized closed.
P1200 Injector COM2 COM2 is op en or short circui ted; o r TWV2, TWV4 or TWV6 is open or

P1210 Capacitor charging circuit (ECU) Malfunction in the injector drive power supply circuit (overcharging or

P1240 Fuel system 1 Large momentary fluctuations in No. 1 cylinder speed.
P1241 Fuel system 5 Large momentary fluctuations in No. 5 cylinder speed.
P1242 Fuel system 3 Large momentary fluctuations in No. 3 cylinder speed.
P1243 Fuel system 6 Large momentary fluctuations in No. 6 cylinder speed.
P1244 Fuel system 2 Large momentary fluctuations in No. 2 cylinder speed.
P1245 Fuel system 4 Large momentary fluctuations in No. 4 cylinder speed.
P1255 Output to SCV Open circuit (e xte r na l) i n ECU te rmi na l SC V+ or SCV-, GND short, or

P1256 Output to SCV BATT short in ECU terminal SCV+ or SCV-.

Injection correction resistance value
Injection correction resistance value
Maximum speed adjusting resistor
Maximum speed adjusting resistor

Injection correction resistance value is too low.

Injection correction resistance value is too high.

Adjusting resistor value is too low.

Adjusting resistor value is too high.

short circuited.

insufficient charging).

open circuit in SCV coil.

P1257 SCV SCV seizure.
P1262 Exhaust brake MV1 Open circuit or GND short in the output to MV1.
P1263 Exhaust brake MV1 BATT short in the output to MV1.
P1605 ECU Malfun ction in th e flash memory.
P1930 Power retarder relay Open circuit, GND short or BATT short in the output to the retarder

relay.

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