Engine Controller.ppt komatsu galeo for engine

Engine Controller

1. GST Nov 2005ECM
Engine Controller

2. Page 2 / 44ECM GST Nov 2005
Contents
Aim of development 3
Controller contour/connectors 4
Power supply connector 4-pin (DTP06-4S) 6
Engine connector 60-pin (DRC26-60S-05) 7
Machine body connector 50-pin (DRC26-50S-04) 8
Environment resistant specifications 9
SAABD107 and 114 engine control system 10
6D125, 140 and 170 engine control system 11
Table of sensors mounted on the engines 12
Engine control matrix 13
Machine-incorporated functions
(engine controller related)
14
Basic flow of data (network) 16
Other functions 17
Service relations (function) 18
Service and parts supply system 19
Dynamo test 20
Engine Ne rotation sensor (crankshaft) 21
About top dead center TDC 22
Engine G rotation sensor (crankshaft) 23
Common rail pressure sensor 24
Charge pressure and temperature sensors 25
Ambient pressure sensor 26
Engine hydraulic switch 27
Water detector sensor (WIF) 28
Coolant temperature sensor 29
Engine oil level sensor 30
Sensor connectors 31
PC200-8 Testing, adjusting and troubleshooting
Measuring gear pump outlet port pressure 34
Measuring fuel leakage from pressure limiter 35
Measuring fuel return from injector 36
Standard value for fuel return 37
Removal and installation of injector 38
PC200-8 Monitoring Code List
(Engine relations)
39
PC200-8 Error code list
Engine relations
40
Troubleshooting of electrical system (E-42) 41
Troubleshooting of electrical system (E-50) 43
PC200-8 Fuel system diagram 44

3. Page 3 / 44ECM GST Nov 2005
Aim of development
1.1.Development of common engines applicable to Komatsu's next Development of common engines applicable to Komatsu's next
generation emission control compliance engine familygeneration 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
2.2.Development of communization between Komatsu and Cummins Development of communization between Komatsu and Cummins
brandsbrands
Coexistence of production and service interfaces
Sharing software development tool
3.3.Development of engine mount structureDevelopment of engine mount structure
Improved engine production and service
4.4.Sharing hardware for mass production engines by CumminsSharing 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

4. Page 4 / 44ECM GST Nov 2005
CM870 / CM850 ASSEMBLY
4-4-00
Controller contour/connector 1/2
280.4
226.1
24.8
52.7
100.2
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 harnessDRC26-50S-04 0528-001-5005
52.7

5. Page 5 / 44ECM GST Nov 2005
Controller contour/connector 2/2
4-pin power
supply
60-pin engine
50-pin machine body
107 engine controller mounting bracket
(Protection from the heat by thermal insulation effect)
ECM : Electronic Control Module

6. Page 6 / 44ECM GST Nov 2005
50-pin
machine
body
60-pin
engine
4-pin power
supply
Power supply connector 4-pin (DTP06-4S)
1Battery power supply (-)
2Battery power supply (-)
3Battery power supply (+)
4Battery power supply (+)

7. Page 7 / 44ECM GST Nov 2005
Engine connector 60-pin (DRC26-60S-05)
Pin No.1
Pin No.60
50-pin
machine
body
60-pin
engine
4-pin power
supply

8. Page 8 / 44ECM GST Nov 2005
Machine body connector 50-pin (DRC26-50S-
04)
Pin No.1
Pin No.50
50-pin
machine
body
60-pin
engine
4-pin power
supply

9. Page 9 / 44ECM GST Nov 2005
Environment resistant specifications
●<Principal environment resistant items><Principal environment resistant items>
●Actuating temperature: Ambient -40 to +105CActuating temperature: Ambient -40 to +105C
Vertical
Front-rear
Horizontal

10. Page 10 / 44ECM GST Nov 2005
SAA6D107 and 114 engine control system
* Dark current prevention: Prevents
ECM current consumption and self-
discharge of battery
Service connector
Main pulse
Engine speed and position
Backup pulse
Injection control
Injector #1
Injector #2
Injector #3
Injector #4
Injector #5
Injector #6
Fuel rail pressure
Emission control
Charge pressure
Charge temperature
Ambient pressure
Engine monitor
Oil pressure switch
Coolant temperature
WIF (Water detection)
Engine
controller
Key switch
Idle validation SW1
Idle validation SW2
Throttle (fuel dial)
Power train relay
Fuel feed pump (117 Eng only)
Power supply 1 (+)
Power supply 2 (+)
Power supply 1 (-)
Power supply 2 (-)
Machine monitor
(panel)
Machine controller
#1 (pump controller)
Machine controller #2
(example: transmission
controller)
Communications via KOMNET
Transmitted to engine controller
1. LSI control
2. HSI control
3. AS control
Throttle command
Throttle limit
Throttle adjustment
4. Power mode selection
5. Cylinder cut-out
No-injection cranking
Theft prevention

Received from engine controller
1. Engine operation information
speed and output torque
2. Error code
3. Monitoring information

11. Page 11 / 44ECM GST Nov 2005
6D125, 140 and 170 engine control system
Service connector
Main pulse
Engine speed and position
Backup pulse
Injection control
Injector #1
Injector #2
Injector #3
Injector #4
Injector #5
Injector #6
Fuel rail pressure
Emission control
Charge pressure
Charge temperature
Ambient pressure
Engine monitor
Supply pump #1
Supply pump #2
EGR valve control
Fuel temperature
Bypass valve control
EGR valve inlet port pressure
EGR valve lift control
Bypass valve lift control
Ambient temperature
Oil pressure sensor
Coolant temperature
(optional)Oil temperature
Exhaust temperature #1
Exhaust temperature #2
Blow-by
Key switch
Idle validation SW1
Idle validation SW2
Throttle (fuel dial)
Power supply 1 (+)
Power supply 2 (+)
Power supply 1 (-)
Power supply 2 (-)
Inlet heater sub-relay
Machine monitor
(panel)
Machine controller #1
(example: transmission
controller)
Machine controller #2
(example: brake controller)
Communications via
KOMNET
Transmitted to engine
controller
1. LSI control
2. HSI control
3. AS control
Throttle command
Throttle limit
Throttle adjustment
4. Power mode selection
5. Cylinder cut-out
No-injection cranking
Theft prevention

Received from engine controller
1.Engine operation information
speed and output torque
2. Error code
3. Monitoring information

12. Page 12 / 44ECM GST Nov 2005
Table of sensors mounted on the engines
3. Table of sensors mounted on the tertiary emission control compliance engines
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)
Sensor name
*1 Integrated charge pressure and
temperature sensor

13. Page 13 / 44ECM GST Nov 2005
Engine control matrix
Engine control matrix
Control function
Tertiary emission
control
Tertiary emission control
Secondary
emission control
Secondary
emission control
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Starting Main
injection
(Split injection)
Injection capacity
Injection timing
Injection pressure
Injection capacity
Injection intervals
Injection capacity
Injection intervals
Injection capacity
Injection timing
Injection pressure
Injection capacity
Injection intervals
Injection capacity
Injection intervals
Injection capacity
Injection timing
Injection pressure
Injection capacity
Injection timing
Injection pressure
Pilot injection
Post injection
Automatic warming-up
Li revolution control
Turbo protection Accelerator position
control
Normal operation
Cold time
Main injection
Pilot injection
Post injection
Main injection
Cold closing control
(Full Q only)
Transition time
Automatic high
altitude correction
(Charge control Q)
EGR/EP valve
Transition time control
BP reverse prevention (bypass
valve)
Inlet heater control Relay drive
Main injection (V140 only)
(V140 only)
(V140 only)

14. Page 14 / 44ECM GST Nov 2005
Machine-incorporated functions 1/2
(engine controller related)
KOMNET-
related
functionsFunction Outline
PC BL WA HD/HM
1. Accelerator fuel dial interface/
(1)Recognition of position signal
for accelerator pedal, fuel dial,
and decel pedal
Recognizes the pedal and/or dial
position according to the voltage
-
Fuel dial Desel pedal Accelerator pedal
(2)Zero-point learning functionLearns 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
position according to KOMNET command.
(For controlling hydraulic
driven fan engine output for
PC600 or higher)
(throttle dial))
(Transmission
interlock control)
(2)Torque control
(partial performance)
Controls torque with equal horsepower
control (mid range governor) through
accelerator position
(For controlling hydraulic
driven fan engine output
for PC600 or higher)
(For controlling
engine output for
D155 only)
(3)Regulation control 2
(partial performance)
Max. rpm control. Controls HIS governor
break point rpm according to KOMNET
command
(4)Throttle upper limit
control
Controls higher value of accelerator position
according to KOMNET command. For Auto-Decel control
(5)Throttle lower limit
control
Controls lower value of accelerator position
according to KOMNET command. (Li up,
accelerator lock)
(6)Governor mode
selection
Selects all speed or mid range governor
(For controlling engine
output for D155 only)
(7)Power mode selection Selects power curve according to
KOMNET command 4 mode
(8)Regulation control
(partial performance)
All speed control (selects combination of
droop SW/ABS and HSI)
3 mode
(All speed/PC500 or
higher mid range)
(All speed/PC600 or
higher mid range)
(All speed)(Mid range))
(9)Li selection (automatic
warming-up)
To reduce cold warming-up time, functions are
provided for selecting Li according to the coolant
temperature, time, and cancellation with KOMNET)
Accelerator pedal
(Transmission
interlock control)
(For controlling hydraulic
driven fan engine output
for PC600 or higher)
(For controlling
engine output for
D155 only)
For Auto-Decel
control
(Li up,
accelerator lock)

15. Page 15 / 44ECM GST Nov 2005
Machine-incorporated functions 2/2
(engine controller related)
3. Protection/Compensation function
(1) Automatic
preheating/post heating
(Auto preheat)
To improve cold startability, grid heater is driven for
a set time depending on the water/intake air
temperature. Preheating displayed on the indicator
(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 correctionCorrects fuel injection capacity according to the spill
fuel temperature (not with B and C engines)
-
(5)Automatic high altitude
compensation
To protect engine, engine output, injection timing
and injection pressure are controlled depending on
the Ambient condition.
-
4. Communication/Troubleshooting function
(1)KOM-NET/c communication
(monitoring)
Receives commands via KOMNET and
transmits sensor signals and internal signals.
(2)Self-diagnosis
(error code indication)
Detects and takes measures for a failure, simultaneously
transmitting error code with J1939. Error code is converted
to a 6-digit code for display on the panel
Hydraulic pressure drop, overheat, and WIF(3)Caution indication
(4)Cylinder cut-off functionTo discriminate a failing injector from the
panel, a random selected cylinder can be
stopped.
(5)No-injection cranking
Injection of all cylinders are stopped from
the panel.
(6)Theft prevention Step2Engine start enabled from the panel by
checking password (PC200,)
5. Machine management
(1)
Measures for preventing
buttery consumption while the
key is OFF
Dark current is eliminated by turning the rely,
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
KOMNET-
related
functions
Function Outline
PC BL WA HD/HM

16. Page 16 / 44ECM GST Nov 2005
Basic flow of data (network)
 Transmission of error code
 Fast processing speed
 Serves as the master
controller
Medium to small type hydraulic excavators
Monitor Engine controller Pump controller
Monitor Engine controller Engine controller Pump controller 1 Pump controller 2
Unicast RTCDB
Unicast RTCDB
Large type hydraulic excavator

17. Page 17 / 44ECM GST Nov 2005
Other functions
Automatic high altitude compensation functionAutomatic 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 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)

18. Page 18 / 44ECM GST Nov 2005
Service relations (function)
1).1).Troubleshooting and data monitoring from machine Troubleshooting and data monitoring from machine
monitor panelmonitor panel
6-digit error code, monitoring function (via KOMNET)6-digit error code, monitoring function (via KOMNET)
2).2).Operation in reduced cylinder modeOperation in reduced cylinder mode
Operation is enabled from the monitor panel via KOMNETOperation is enabled from the monitor panel via KOMNET..
3).3).No-injection cranking functionNo-injection cranking function
Operation is enabled from the monitor panel via KOMNET.Operation is enabled from the monitor panel via KOMNET.
4).4).Dynamo testDynamo test
Cummins dynamo tool of INSITE is used (common with Cummins dynamo tool of INSITE is used (common with
downloader tool)downloader tool)

19. Page 19 / 44ECM GST Nov 2005
Service and parts supply system
1. Controller supply 1. Controller supply and writing are covered by and writing are covered by
replacing assemblyreplacing assembly (plant is responsible for the writing)(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 controllers2. 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

20. Page 20 / 44ECM GST Nov 2005
Dynamo test
ECM
Engine
ECMThrottle box
PC
PC
Throttle box
Next generation emission control
Secondary emission control (125 and 140)
(Download)
Engine
Battery
Battery
(Identical configuration
with the current 170)
Writing and output adjustment are disabled

21. Page 21 / 44ECM GST Nov 2005
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
TDC sensory notch
Rotating ring
Ne rotation
sensor

22. Page 22 / 44ECM GST Nov 2005
About top dead center TDC
1 to 6 reaches TDC when this groove and
stamped TDC are at position (P) overhead

Rotate the position in the photo to the left
72
degrees to the right to attain TDC for 1 to 6
Notch on the rotating ring
matches Ne sensor
Directly
overhead
position
72 degrees to
the left
Position with TDC stamping and a
groove (on the circumference of the
damper)

23. Page 23 / 44ECM GST Nov 2005
Engine G rotation sensor (crankshaft)
Major functions
Senses a combusting cylinder
Applies the Hall element effect
G rotation sensor
Six (6) plus 1 grooves are
cut to the end of camshaft

24. Page 24 / 44ECM GST Nov 2005
Common rail pressure sensor
Common rail pressure sensor
Major functions
Common rail internal pressure control

25. Page 25 / 44ECM GST Nov 2005
Charge pressure and temperature sensors
Charge pressure and
temperature sensors
Major functions
Determining fuel for injection
Intake air preheating control

26. Page 26 / 44ECM GST Nov 2005
Ambient pressure sensor
Ambient
pressure sensor
Major functions
Automatic altitude compensation and
fuel injection

27. Page 27 / 44ECM GST Nov 2005
Engine hydraulic switch
Hydraulic switch
Major functions
Warning to hydraulic pressure drop
Protection of turbocharger

28. Page 28 / 44ECM GST Nov 2005
Water detector sensor (WIF)
Water-presence sensor
Major functions
Senses water level in the fuel prefilter
Warns high or low water level

29. Page 29 / 44ECM GST Nov 2005
Engine coolant temperature sensor
Control functions
Monitors temperature and warns overheating
Determining fuel for injection
Automatic warming-up
Protection of turbocharger
Coolant temperature sensor

30. Page 30 / 44ECM GST Nov 2005
Engine oil level sensor
Warning to abnormally low engine oil
level

31. Page 31 / 44ECM GST Nov 2005
Sensor connectors 1/2
3-pin harness connector
1.In locked condition 2.Sliding the lock 3. Withdraw the lock by
pressing the knob

32. Page 32 / 44ECM GST Nov 2005
Sensor connectors 2/2
Connector with lock,
charge sensor, etc.

33. GST Nov 2005ECM
PC200-8 Testing, adjusting and
troubleshooting

34. Page 34 / 44ECM 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
pressure
fuel circuit
pressure
At cranking time
(when starting disabled)
At low idling time
(when starting enabled)

35. Page 35 / 44ECM GST Nov 2005
Measuring fuel leakage from pressure limiter
Measure leakage as a means for judging
pressure limiter performance
No leakage if normal
(1) Leak from
pressure
limiter
Fuel cooler Tank
return connection
(2) Injector return
(3) Supply pump drain
Leakage
outlet port
Pressure limiter

36. Page 36 / 44ECM GST Nov 2005
Measuring fuel return from injector
Reference value for measured return capacity: Engine
in low idling/30 sec
(2) Injector: 40 cc (3) Pump: 400 cc
Swing lock or arm relief time/30 sec.
(2) Injector: 90 cc (3) Pump: 440 cc
Measure the return capacity as a means
for determining the injector performance
(2)
(3)
(1) Leak from
pressure
limiter
Fuel cooler Tank
return connection
(2) Injector return
(3) Supply pump drain

37. GST Nov 2005ECM
Standard value for fuel return
Measuring return
capacity from injector
Estimated causes of leakage and standard value
under normal condition
Defective pressure
limiter
For checking leak from the pressure limiter, see the
"Checking on fuel return and leakage" in Checking and
Adjusting section.
Pressure limiter
leakage
At low idling time 0 cc (no leakage)
Defective pressure
(including high
pressure piping
inside the head)
For checking leak capacity from the injector, see the "Checking on
fuel return and leakage" in Checking and Adjusting section.
Injector return
capacity
At cranking time (when
starting disabled)
At low idling time
(when starting
enabled)
Defective
supply pump
For checking return capacity from the supply pump, see the "Checking
on fuel return and leakage" in Checking and Adjusting section.
Return capacity
from supply pump
At cranking time (when
starting disabled)
At low idling time (when
starting enabled)

38. GST Nov 2005ECM
Removal and
installation of injector
1. Apply engine oil to the O-ring on the injector and the
portion inserted to the head
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
for temporary tightening)
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
(1)
(2)
(3)(4)

39. GST Nov 2005ECM
Monitoring display item nameMonitoring ID
Name of
component to
become the
data server
CM
850
ENG
(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 --
Unit
PC200-8 Monitoring Code List (Engine relations)

40. Page 40 / 44ECM GST Nov 2005
PC200-8 Error Code List (Engine relations)
6 figure codeName by the monitor User code

6 figure codeName 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
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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41. GST Nov 2005ECM
Troubleshooting of electrical system (E-42) 1/2
Error is output if a state of minus (-) 100 bar to target
pressure value persists for 5 seconds
Remarks:
E-42 code [559/CA559] supply pump no feed abnormality 1
Error code
Content of failure
Failure code
Faulty
phenomenon Supply pump no feed abnormality 1
• No feed abnormality (1) generated to common rail circuit
Action by
controller
• No particular action
Phenomenon
appearing on
machine
• Engine not starting or poor startability
• Exhaust color is blackish
• Engine output drops
Related
information
• Reproduction method of a failure code: Start engine

42. GST Nov 2005ECM
Troubleshooting of electrical system (E-42) 2/2
Estimated
causes of
troubles and
standard
value under
normal
condition
Cause Normal standard value and remarks for diagnosis
External leakage of fuel
Direct visual check (with engine at low idling) for possible
external leakage of fuel
Defective low-pressure
circuit equipment
For checking low-pressure fuel circuit pressure, see the "Checking
on fuel pressure" in Checking and Adjusting section.
Low pressure Low pressure
fuel circuit fuel circuit
pressure pressure
At cranking time (when
starting disabled)
At low idling time (when
starting enabled)
Defective pressure limiter
For checking leak from the pressure limiter, see the "Checking on
fuel return and leakage" in Checking and Adjusting section.
Pressure limiter Pressure limiter
leakageleakage
At low idling time 0 cc (no leakage)
Defective pressure
(including high pressure
piping inside the head)
For checking a return capacity from the injector, see the "Checking
on fuel return and leakage" in Checking and Adjusting section.
Injector return Injector return
capacity capacity
At cranking time (when
starting disabled)
At low idling time (when
starting enabled)
Defective supply pump
 For checking return capacity from the supply pump, see the "Checking on
fuel return and leakage" in Checking and Adjusting section.
Return capacity Return capacity
from supply from supply
pumppump
At cranking time (when
starting disabled)
At low idling time (when
starting enabled)

43. GST Nov 2005ECM
Troubleshooting of electrical system (E-50)
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
Remarks: Error is indicated via the following two processes:
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
appearing on
machine
• Poor engine startability
• Exhaust color is blackish
• Engine output drops
Related
information
•Reproduction method of a failure code: Start engine
Estimated causes
of troubles and
standard value
under normal
condition
Cause Normal standard value and remarks for diagnosis
Implement troubleshooting for failure code [CA559]

44. GST Nov 2005ECM
PC200-8 Fuel system diagram
(1) Pressure limiter 1,850 bar
(2) Relief valve 105 bar to 13 bar
*
Pressure limiter
Common rail
Injector
Return
check
valve
Overflow valve
Main filter
Priming pump
Supply pump
IMV valve
Gear pump
Prefilter
Fuel tank
Fuel cooler
(4) Return Check valve 0.48 bar
(3) Bypass valve 0.1 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
choke to retain the state of zero-delivery
Normally no fuel flows