ISUZU 4HK1 -6HK1 Engine Electrical Toubleshooting manual

TROUBLESHOOTING MANUAL 4HK1-6HK1 ISUZU ENGINE Workshop manual integration of the following models: E385 (Tier 3) R3807 R3807 All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice. NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. - PRODUCT SUPPORT FORM No. 604.13.654 - Edition - January 2006

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. For any question or comment, or should you notice any mistake concerning the content of this manual, please contact: NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY Strada Settimo, 323 San Mauro Torinese (TO) 10099 ITALIA PRODUCT SUPPORT Fax ++39 011 0077357

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 How to read trouble diagnosis section . . . . . . . 1E-8 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 CNH - EST Diagnostic tool . . . . . . . . . . . . . . . 1E-20 How to Inspect Injector . . . . . . . . . . . . . . . . . . 1E-22 How to use injector checker . . . . . . . . . . . . . . 1E-22 Method to identify using non-contact infrared thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-26 How to use flash tool . . . . . . . . . . . . . . . . . . . . . 1E-28 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-28 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-29 EMPS Component Parts . . . . . . . . . . . . . . . . 1E-31 ECM (Hardware) Compatibility . . . . . . . . . . . . 1E-32 System Requirements for EMPS Software (Recommended) . . . . . . . . . . . . . . . . . . . . . . 1E-32 EMPS (Software) Setup Procedure . . . . . . . . 1E-33 EMPS Operation Procedure . . . . . . . . . . . . . . 1E-37 How to use breaker box . . . . . . . . . . . . . . . . . . 1E-79 Engine Control System . . . . . . . . . . . . . . . . . . . 1E-82 Description of function and operation . . . . . . . 1E-82 Engine Control Module (ECM) . . . . . . . . . . . . 1E-91 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . 1E-112 Engine harness location . . . . . . . . . . . . . . . . 1E-128 Connector list . . . . . . . . . . . . . . . . . . . . . . . . 1E-140 List of function checks . . . . . . . . . . . . . . . . . . . 1E-143 OBD system check . . . . . . . . . . . . . . . . . . . . 1E-144 Diagnosis lamp illumination circuit system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-146 Diagnosis lamp blinking circuit system check 1E-148 Scan tool power supply circuit system check 1E-151 Scan tool communication circuit system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-153 Starting circuit system check . . . . . . . . . . . . 1E-156 Starting system check . . . . . . . . . . . . . . . . . 1E-162 Fuel system check . . . . . . . . . . . . . . . . . . . . 1E-165 Intake system check . . . . . . . . . . . . . . . . . . . 1E-167 Exhaust system check . . . . . . . . . . . . . . . . . 1E-168 EGR control system check . . . . . . . . . . . . . . 1E-169 QOS system check . . . . . . . . . . . . . . . . . . . . 1E-172 List of diagnostic trouble code . . . . . . . . . . . . . 1E-177 DTC: P0087 (Flash code 227) Common rail low pressure fault (No pressure feed in supply pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-201 DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage) . . . . . . 1E-209 DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in supply pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-214 DTC: P0090 (Flash code 247) SCV drive system open circuit, +B short or ground short . . . . . 1E-219 DTC: P0107 (Flash code 71) Barometric pressure sensor circuit input is low (open circuit or ground short). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-225 DTC: P0108 (Flash code 71) Barometric pressure sensor circuit input is high (+5 V short) . . . . 1E-232 DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND short, short circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-239 DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open circuit or short to power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-245 DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault, GND short, short circuit) . . . . . . . . . . . . . . . . . . . . 1E-253 DTC: P0118 (Flash code 23) Engine coolant temperature sensor input is high (open circuit or short to power supply) . . . . . . . . . . . . . . . . . . . . . . 1E-260 DTC: P0182 (Flash code 211) Fuel temperature sensor fault (low voltage fault, GND short) . . 1E-268 DTC: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open circuit or short to power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-274 DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short circuit) . 1E-282 DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault) . . . . . . . . . . 1E-288 DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system . . . . . . . . . . 1E-295 DTC: P0202 (Flash code 272) Open circuit in injection nozzle #2 drive system . . . . . . . . . . 1E-302 DTC: P0203 (Flash code 273) Open circuit in injection nozzle #3 drive system . . . . . . . . . . 1E-309 DTC: P0204 (Flash code 274) Open circuit in injection nozzle #4 drive system . . . . . . . . . . 1E-316

1E-2 Electronic control fuel injection system (Common rail type) DTC: P0205 (Flash code 275) Open circuit in injection nozzle #5 drive system . . . . . . . . . 1E-323 DTC: P0206 (Flash code 276) Open circuit in injection nozzle #6 drive system . . . . . . . . . 1E-328 DTC: P0219 (Flash code 543) Overrun . . . . 1E-333 DTC: P0237 (Flash code 32) Boost sensor pressure fault (low voltage fault, open circuit) . . . . . . . 1E-335 DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault, short to power supply circuit, ground open circuit) . . . . . . . . . . . . . . . . . . . 1E-343 DTC: P0335 (Flash code 15) Crank sensor fault (no signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-351 DTC: P0336 (Flash code 15) Crank sensor fault (signal fault) . . . . . . . . . . . . . . . . . . . . . . . . . 1E-358 DTC: P0340 (Flash code 14) Cam sensor fault (no signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-364 DTC: P0341 (Flash code 14) Cam sensor fault (signal fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-371 DTC: P0380 (Flash code 66) Glow relay circuit fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-377 DTC: P0381 (Flash code 67) Glow plug lamp circuit fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-382 DTC: P0487 (Flash code 44) EGR position sensor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-387 DTC: P0488 (Flash code 45) EGR valve control fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-393 DTC: P0522 (Flash code 294) Engine oil pressure sensor fault (low voltage fault, open circuit, ground short) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-399 DTC: P0523 (Flash code 295) Engine oil pressure sensor fault (high voltage fault, short to power supply, ground short) . . . . . . . . . . . . . . . . . . . . . . . . 1E-405 DTC: P0601 (Flash code 53) ROM fault . . . 1E-413 DTC: P0603 (Flash code 54) EEPROM fault 1E-415 DTC: P0606 (Flash code 51/52) CPU fault . 1E-417 DTC: P0611 (Flash code 34) Charge circuit fault (bank 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-419 DTC: P0612 (Flash code 34) Charge circuit fault (bank 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-422 DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-425 DTC: P1093 (Flash code 227) No pump pressure feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-430 DTC: P1095 (Flash code 225) Pressure limiter open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-439 DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground short) 1E-449 DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open circuit, short to power supply circuit) . . . . . . . . . . . . . . . . . . 1E-457 DTC: P1173 (Flash code 542) Overheat . . . 1E-463 DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-469 DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault . . . . . . . . . . . . 1E-473 DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault . . . . . . . . . . . . 1E-484 DTC: P1271 (Flash code 24) Accelerator sensor 1-2 comparison fault . . . . . . . . . . . . . . . . . . . . . . 1E-495 DTC: P1277 (Flash code 24) Accelerator sensor 1 fault (low voltage fault) . . . . . . . . . . . . . . . . . 1E-501 DTC: P1278 (Flash code 24) Accelerator sensor 1 fault (high voltage fault) . . . . . . . . . . . . . . . . 1E-506 DTC: P1282 (Flash code 24) Accelerator sensor 2 fault (low voltage fault) . . . . . . . . . . . . . . . . . 1E-511 DTC: P1283 (Flash code 24) Accelerator sensor 2 fault (high voltage fault) . . . . . . . . . . . . . . . . 1E-516 DTC: P1345 (Flash code 16) Cam sensor out of phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-521 DTC: P1625 (Flash code 416) Main relay fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-526 DTC: P1630 (Flash code 36) A/D conversion fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-533 DTC: P1631 (Flash code 55) Voltage fault in 5-V power supply 1 . . . . . . . . . . . . . . . . . . . . . . . 1E-535 DTC: P1632 (Flash code 55) Voltage fault in 5-V power supply 2 . . . . . . . . . . . . . . . . . . . . . . . 1E-538 DTC: P1633 (Flash code 55) Voltage fault in 5-V power supply 3 . . . . . . . . . . . . . . . . . . . . . . . 1E-541 DTC: P1634 (Flash code 55) Voltage fault in 5-V power supply 4 . . . . . . . . . . . . . . . . . . . . . . . 1E-544 DTC: P1635 (Flash code 55) Voltage fault in 5-V power supply 5 . . . . . . . . . . . . . . . . . . . . . . . 1E-550 List of trouble symptom . . . . . . . . . . . . . . . . . . 1E-551 Engine start failure . . . . . . . . . . . . . . . . . . . . 1E-555 Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-565 Engine hunting, rough idling . . . . . . . . . . . . . 1E-559 Engine output shortage . . . . . . . . . . . . . . . . 1E-563 Exhaust gas contains a lot of white smoke. . 1E-568 Exhaust gas contains a lot of black smoke. . 1E-571 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-574 Fuel consumption deteriorates. . . . . . . . . . . 1E-576 Oil consumption deteriorates. . . . . . . . . . . . . 1E-579 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-581

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 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 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. SIG Signal Signal

Electronic control fuel injection system (Common rail type) 1E-5 List of parts according to engine control specifications 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 m m Controls the fuel pressure feed of supply pump. SCV m m m Controls the fuel pressure feed of supply pump. CMP sensor m m m Detects camshaft position of engine (used for identifying cylinder.) G sensor m m Detects cam position of supply pump (used for identifying cylinder.) CKP sensor m m m m m Detects crankshaft position (used for engine control in general.) Abbreviation Name Meaning and remarks

ISUZU 4HK1 -6HK1 Engine Electrical Toubleshooting manual

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