HITACHI ISUZU 4H & 6H Engine Service Manual

Introduction This Troubleshooting Manual describes the structure and the troubleshooting of electronic control fuel injection system (common rail type) in 4HK1 and 6HK1 industrial engines. Use this manual sufficiently to perform service work properly and quickly. Isuzu Motors Limited Off-highway Powertrain Operation Dept.

Control System Engine Control (Electronic control fuel injection system (Common rail type)) Table of Contents How to use this manual . . . . . . . . . . . . . . . . . . . . 1E-3 Table of abbreviation . . . . . . . . . . . . . . . . . . . . . 1E-4 List of parts according to engine control specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-5 About colors of wirings . . . . . . . . . . . . . . . . . . . 1E-6 About wiring diagrams. . . . . . . . . . . . . . . . . . . . 1E-7 Precautions on Service Work . . . . . . . . . . . . . . . 1E-10 Procedure of trouble diagnosis . . . . . . . . . . . . . 1E-11 Interview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-13 Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1E-15 Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . . 1E-15 How to read DTC . . . . . . . . . . . . . . . . . . . . . . 1E-16 Confirmation after repair . . . . . . . . . . . . . . . . . 1E-18 List of final check items . . . . . . . . . . . . . . . . . . 1E-18 How to clear DTC . . . . . . . . . . . . . . . . . . . . . . 1E-19 Trouble diagnosis with scan tool . . . . . . . . . . . 1E-20 How to use trouble diagnosis-related tool . . . . . 1E-25 How to use Tech2 . . . . . . . . . . . . . . . . . . . . . . 1E-25 Injector balance test . . . . . . . . . . . . . . . . . . . . 1E-43 Rewrite setting of Q adjust data by Tech2. . . . 1E-48 How to use TIS 2000. . . . . . . . . . . . . . . . . . . . 1E-68 How to Inspect Injector. . . . . . . . . . . . . . . . . . . . 1E-78 How to use injector checker . . . . . . . . . . . . . . 1E-78 Method to identify using non-contact infrared thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-82 How to use flash tool . . . . . . . . . . . . . . . . . . . . 1E-84 How to use breaker box . . . . . . . . . . . . . . . . . 1E-85 Engine Control System . . . . . . . . . . . . . . . . . . . 1E-88 Description of function and operation . . . . . . . 1E-88 Engine Control Module (ECM) . . . . . . . . . . . . 1E-97 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . 1E-118 Engine harness location . . . . . . . . . . . . . . . . 1E-134 Connector list . . . . . . . . . . . . . . . . . . . . . . . . 1E-146 List of function checks . . . . . . . . . . . . . . . . . . . 1E-149 OBD system check . . . . . . . . . . . . . . . . . . . . 1E-150 Diagnosis lamp illumination circuit system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-152 Diagnosis lamp blinking circuit system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-154 Scan tool power supply circuit system check 1E-157 Scan tool communication circuit system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-159 Starting circuit system check . . . . . . . . . . . . . 1E-162 Starting system check . . . . . . . . . . . . . . . . . . 1E-168 Fuel system check . . . . . . . . . . . . . . . . . . . . 1E-171 Intake system check . . . . . . . . . . . . . . . . . . . 1E-173 Exhaust system check . . . . . . . . . . . . . . . . . 1E-174 EGR control system check . . . . . . . . . . . . . . 1E-175 QOS system check . . . . . . . . . . . . . . . . . . . . 1E-178 List of diagnostic trouble code . . . . . . . . . . . . . 1E-183 DTC: P0087 (Flash code 227) Common rail low pressure fault (No pressure feed in supply pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-207 DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage) . . . . . . 1E-215 DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in supply pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-220 DTC: P0090 (Flash code 247) SCV drive system open circuit, +B short or ground short . . . . . . 1E-225 DTC: P0107 (Flash code 71) Barometric pressure sensor circuit input is low (open circuit or ground short). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-231 DTC: P0108 (Flash code 71) Barometric pressure sensor circuit input is high (+5 V short) . . . . . 1E-238 DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND short, short circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-245 DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open circuit or short to power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-251 DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault, GND short, short circuit) . . . . . . . . . . . . . . . . . . . . . 1E-259 DTC: P0118 (Flash code 23) Engine coolant temperature sensor input is high (open circuit or short to power supply) . . . . . . . . . . . . . . . . . . . . . . 1E-266 DTC: P0182 (Flash code 211) Fuel temperature sensor fault (low voltage fault, GND short) . . 1E-274 DTC: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open circuit or short to power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-280 DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short circuit) . 1E-288 DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault) . . . . . . . . . . . 1E-294 DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system . . . . . . . . . . 1E-301 DTC: P0202 (Flash code 272) Open circuit in injection nozzle #2 drive system . . . . . . . . . . 1E-308 DTC: P0203 (Flash code 273) Open circuit in injection nozzle #3 drive system . . . . . . . . . . 1E-315 DTC: P0204 (Flash code 274) Open circuit in injection nozzle #4 drive system . . . . . . . . . . 1E-322 DTC: P0205 (Flash code 275) Open circuit in injection nozzle #5 drive system . . . . . . . . . . 1E-329 DTC: P0206 (Flash code 276) Open circuit in injection nozzle #6 drive system . . . . . . . . . . 1E-334

1E-2 Electronic control fuel injection system (Common rail type) DTC: P0219 (Flash code 543) Overrun . . . . 1E-339 DTC: P0237 (Flash code 32) Boost sensor pressure fault (low voltage fault, open circuit) . . . . . . . 1E-341 DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault, short to power supply circuit, ground open circuit) . . . . . . . . . . . . . . . . . . . 1E-348 DTC: P0335 (Flash code 15) Crank sensor fault (no signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-355 DTC: P0336 (Flash code 15) Crank sensor fault (signal fault). . . . . . . . . . . . . . . . . . . . . . . . . . 1E-362 DTC: P0340 (Flash code 14) Cam sensor fault (no signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-368 DTC: P0341 (Flash code 14) Cam sensor fault (signal fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-375 DTC: P0380 (Flash code 66) Glow relay circuit fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-381 DTC: P0381 (Flash code 67) Glow plug lamp circuit fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-386 DTC: P0487 (Flash code 44) EGR position sensor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-391 DTC: P0488 (Flash code 45) EGR valve control fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-397 DTC: P0522 (Flash code 294) Engine oil pressure sensor fault (low voltage fault, open circuit, ground short) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-403 DTC: P0523 (Flash code 295) Engine oil pressure sensor fault (high voltage fault, short to power supply, ground short) . . . . . . . . . . . . . . . . . . . . . . . . . 1E-409 DTC: P0601 (Flash code 53) ROM fault . . . . 1E-417 DTC: P0603 (Flash code 54) EEPROM fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-419 DTC: P0606 (Flash code 51/52) CPU fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-421 DTC: P0611 (Flash code 34) Charge circuit fault (bank 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-423 DTC: P0612 (Flash code 34) Charge circuit fault (bank 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-426 DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-429 DTC: P1093 (Flash code 227) No pump pressure feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-434 DTC: P1095 (Flash code 225) Pressure limiter open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-443 DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground short) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-452 DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open circuit, short to power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-460 DTC: P1173 (Flash code 542) Overheat . . . . 1E-466 DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-472 DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault . . . . . . . . . . . . 1E-476 DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault . . . . . . . . . . . . 1E-487 DTC: P1271 (Flash code 24) Accelerator sensor 1-2 comparison fault . . . . . . . . . . . . . . . . . . . . . . 1E-498 DTC: P1277 (Flash code 24) Accelerator sensor 1 fault (low voltage fault) . . . . . . . . . . . . . . . . . 1E-504 DTC: P1278 (Flash code 24) Accelerator sensor 1 fault (high voltage fault) . . . . . . . . . . . . . . . . . 1E-509 DTC: P1282 (Flash code 24) Accelerator sensor 2 fault (low voltage fault). . . . . . . . . . . . . . . . . . 1E-514 DTC: P1283 (Flash code 24) Accelerator sensor 2 fault (high voltage fault) . . . . . . . . . . . . . . . . . 1E-519 DTC: P1345 (Flash code 16) Cam sensor out of phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-524 DTC: P1625 (Flash code 416) Main relay fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-529 DTC: P1630 (Flash code 36) A/D conversion fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-536 DTC: P1631 (Flash code 55) Voltage fault in 5-V power supply 1 . . . . . . . . . . . . . . . . . . . . . . . 1E-538 DTC: P1632 (Flash code 55) Voltage fault in 5-V power supply 2 . . . . . . . . . . . . . . . . . . . . . . . 1E-541 DTC: P1633 (Flash code 55) Voltage fault in 5-V power supply 3 . . . . . . . . . . . . . . . . . . . . . . . 1E-544 DTC: P1634 (Flash code 55) Voltage fault in 5-V power supply 4 . . . . . . . . . . . . . . . . . . . . . . . 1E-547 DTC: P1635 (Flash code 55) Voltage fault in 5-V power supply 5 . . . . . . . . . . . . . . . . . . . . . . . 1E-550 DTC: U2104 (Flash code 84) CAN Bus fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-553 DTC: U2106 (Flash code 85) CAN timeout fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-558 List of trouble symptom . . . . . . . . . . . . . . . . . . 1E-563 Engine start failure. . . . . . . . . . . . . . . . . . . . . 1E-564 Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-568 Engine hunting, rough idling . . . . . . . . . . . . . 1E-572 Engine output shortage . . . . . . . . . . . . . . . . . 1E-576 Exhaust gas contains a lot of white smoke.. . 1E-581 Exhaust gas contains a lot of black smoke.. . 1E-584 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-587 Fuel consumption deteriorates. . . . . . . . . . . . 1E-589 Oil consumption deteriorates. . . . . . . . . . . . . 1E-592 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-594 Difference by each machine manufacturer . . . . 1E-595 Hitachi Construction Machinery Co., Ltd. . . . 1E-595 About wiring diagrams . . . . . . . . . . . . . . . . . . 1E-598

Electronic control fuel injection system (Common rail type) 1E-3 How to use this manual This manual describes about engine-related trouble diagnosis, and is closely related to the machine trouble diagnosis. Always refer to both manuals for the trouble diagnosis. This manual consists of the following contents. This section “How to use this manual” describes about abbreviations and instructions to use this manual. Therefore, if you are familiar with Isuzu manuals, start with Precautions on service work and Basic procedure of trouble diagnosis. How to use this manual • Table of abbreviation • List of parts according to engine control specifications • Wiring color code • How to use wiring diagram Precautions on service work Procedure of trouble diagnosis How to use trouble diagnosis-related tool • How to use scan tool • How to use TIS 2000 • How to use injector checker • How to use flash tool • How to use breaker box Engine control system List of function checks List of diagnostic trouble codes List of trouble symptom

1E-4 Electronic control fuel injection system (Common rail type) Table of abbreviation Abbreviation Name Meaning and remarks A/D Analog/Digital Analog/Digital AP Accelerator Position Accelerator opening angle CAN Controller Area Network Communication system used to communicate between ECM and the machine control unit CKP Crankshaft Position Crankshaft (the sensor is installed onto flywheel housing) position C/U Control/Unit Abbreviation of control unit CMP Camshaft Position Camshaft (the sensor is installed onto the rear of cylinder head) position DLC Data Link Connector Connector for scan tool (also known as: Checker connector) EMPS Engine Module Programming System Rewriting of control program in ECM DMM Digital Multi-Meter Diagnostic tester for electrical equipment system (5- 8840-2691-0) DTC Diagnostic Trouble Code Self-diagnosis code numbers which indicate trouble condition ECT Engine Coolant Temperature Engine coolant temperature ECM Engine Control Module Core of engine control in engine control computer ECU Electronic Control Unit Computer for various control EGR Exhaust Gas Recirculation Recirculation system which mixes exhaust gas from engine with intake air again to lower the combustion temperature resulting in reduction of NOx. EMI Electro Magnetic Interference Electro Magnetic Interference Exh Exhaust Exhaust F/B Feed/Back Abbreviation of feedback FT Fuel Temperature Fuel temperature (the sensor is installed onto supply pump.) GND Ground Ground/Earth IAT Intake Air Temperature Intake air temperature J/C Joint/Connection Connector which connects each harness MIL Malfunction Indicator Lamp Warning lamp MIL (diagnosis lamp) PC Pressure Control Pressure control/Common rail pressure SCV Suction Control Valve Valve which controls fuel flow to common rail and is installed onto supply pump PCV Pressure Control Valve Valve which controls fuel flow to common rail and is installed onto supply pump PWM Pulse Width Modulation Pulse width modulated wave QOS Quick On Start Warming-up device RP Rail Pressure Pressure in common rail SBF Slow Blow Fuse Slow-blow type fuse which protects circuits of battery, motor, etc.

Electronic control fuel injection system (Common rail type) 1E-5 List of parts according to engine control specifications SIG Signal Signal VSS Vehicle Speed Sensor Sensor used to detect vehicle speed to control meters or engine W/S Weld/Splice Joint of each harness without connector Engine Function 6W 6U 6H 4H 4J PCV ❍ ❍ Controls the fuel pressure feed of supply pump. SCV ❍ ❍ ❍ Controls the fuel pressure feed of supply pump. CMP sensor ❍ ❍ ❍ Detects camshaft position of engine (used for identifying cylinder.) G sensor ❍ ❍ Detects cam position of supply pump (used for identifying cylinder.) CKP sensor ❍ ❍ ❍ ❍ ❍ Detects crankshaft position (used for engine control in general.) Abbreviation Name Meaning and remarks

1E-6 Electronic control fuel injection system (Common rail type) About colors of wirings All harnesses are identified by using different colors of claddings. The harness for the main circuit in a certain electrical system is identified by using a single color, while the harness for the sub circuit uses a color in stripes. Sizes and colors coding in a wiring diagram are as follows. Name 1. Single color 2. Color stripe e.g. Red (stripe color) Green (base color) Harness size(0.5mm ) 2 Symbol Color Symbol Color B Black BR Brown W White LG Light green R Red GR Grey G Green P Pink Y Yellow SB Sky blue L Blue V Violet O Orange

Electronic control fuel injection system (Common rail type) 1E-7 About wiring diagrams 1. Sections surrounded by long broken lines are used to indicate the units, such as ECM. 2. Sections surrounded by dotted lines are used to classify or differentiate the specifications of machines. Confirmation of specifications is needed. 3. Sections surrounded by dotted lines and marked with a symbol (“A” in example) on the upper left are used to classify different wiring in the specifications of machines. Confirmation of specifications is needed. 4. Sections surrounded by heavy lines are used to differentiate engine harnesses from other harnesses. Heavy lines indicate engine harnesses, other lines indicate machine harnesses. 108 3 0.75 B 0.5 V/W 0.5 Y 2 1 E-56 2 E-98 1 E-98 19 E-57 107 E-56 106 E-56 3 2 E-93 7 2 E-90 3 E-90 0.75 R 1 E-93 1 E-90 83 E-56 0.75 Y/G 0.75 B/Y 0.75 R/B 0.75 B/Y 0.75 B/Y 0.75 L/Y 0.75 W/B SV 84 E-56 SV SV Vcc 11 1 79 E-56 10 2 67 E-56 9 3 80 E-56 H-20 H-20 H-20 H-6 H-20 H-20 H-20 H-20 E-76 E-76 E-76 4 H-6 A * CAN HIGH CAN LOW 37 E-57 18 E-57 CAN HIGH CAN LOW A TSWG0078 Machine trouble diagnosis monitor Machine control unit Engine control module (ECM) Engine coolant temperature gauge Meter Vehicle speed sensor Fuel temperature sensor Engine oil pressure sensor Engine coolant temperature sensor CKP sensor Engine control module (ECM) Pulse matching box CKP HIGH signal CKP LOW signal Vehicle speed sensor signal Fuel temperature sensor signal Engine coolant temperature sensor signal Engine oil pressure sensor signal TSWG0120 2 3 4 1

HITACHI ISUZU 4H & 6H Engine Service Manual

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