HITACHI ISUZU 6WG1 Engine Service Manual

Introduction Hitachi Construction Machinery Co., Ltd This Manual describes the structure and the troubleshooting of electronic control fuel injection system (common rail type) in 6WG1 industrial engines. Use this manual sufficiently to perform service work properly and quickly.

General Contents Control System Engine Control (Electronic control fuel injection system (Common rail type)) Engine Manual (2/2) Disassemble and Assemble Engine General Information Engine Mechanical (6WG1(Common rail)) Cooling System (6WG1(Common rail)) Fuel System (6WG1(Common rail)) Electrical System (6WG1(Common rail)) Lubricating System (6WG1(Common rail)) Intake System (6WG1(Common rail)) Preheating System (6WG1(Common rail))

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 correction data by Tech2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-48 Injector ID code (No. 1 cylinder − No. 6 cylinder) registration setting using Tech2 . . . . . . . . . . . . 1E-55 ID code upload (Tech2) . . . . . . . . . . . . . . . . . . 1E-63 ID code download (Tech2) . . . . . . . . . . . . . . . . 1E-65 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-96 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . 1E-113 Engine harness location . . . . . . . . . . . . . . . . . 1E-126 Connector list . . . . . . . . . . . . . . . . . . . . . . . . . 1E-132 List of function checks . . . . . . . . . . . . . . . . . . . . 1E-135 OBD system check. . . . . . . . . . . . . . . . . . . . . 1E-136 Diagnosis lamp illumination circuit system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-138 Diagnosis lamp blinking circuit system check 1E-140 Scan tool power supply circuit system check.1E-143 Scan tool communication circuit system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-145 Starting circuit system check . . . . . . . . . . . . . 1E-148 Starting system check . . . . . . . . . . . . . . . . . . 1E-154 Fuel system check . . . . . . . . . . . . . . . . . . . . . 1E-157 Intake system check . . . . . . . . . . . . . . . . . . . . 1E-160 Exhaust system check . . . . . . . . . . . . . . . . . . 1E-161 EGR control system check . . . . . . . . . . . . . . . 1E-162 QOS system check . . . . . . . . . . . . . . . . . . . . 1E-165 List of diagnostic trouble code . . . . . . . . . . . . . . 1E-170 DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage) . . . . . . . 1E-183 DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in supply pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-188 DTC: P0091/P1291 (Flash code 247/248) PCV circuit fault (PCV1 open circuit or GND short circuit/PCV2 open circuit or GND short circuit) . . . . . . . . . . 1E-193 DTC: P0092/P1292 (Flash code 217/218) PCV circuit fault (PCV1+B short circuit / PCV2+B short circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-199 DTC: P0107 (Flash code 71) Barometric pressure sensor circuit input is low (open circuit or ground short) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-204 DTC: P0108 (Flash code 71) Barometric pressure sensor circuit input is high (+5V short) . . . . . . 1E-211 DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND short, short circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-218 DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open circuit or short to power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-224 DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault, GND short, short circuit) . . . . . . . . . . . . . . . . . . . . . 1E-232 DTC: P0118 (Flash code 23) Engine coolant temperature sensor input is high (open circuit or short to power supply) . . . . . . . . . . . . . . . . . . . . . . . 1E-238 DTC: P0182 (Flash code 211) Fuel temperature sensor fault (low voltage fault, GND short) . . . . . . . . . . 1E-246 DTC: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open circuit or short to power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-252 DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short circuit) . .1E-260 DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault, open circuit) .1E-266 DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system . . . . . . . . . . 1E-273 DTC: P0202 (Flash code 272) Open circuit in injection nozzle #2 drive system . . . . . . . . . . 1E-278 DTC: P0203 (Flash code 273) Open circuit in injection nozzle #3 drive system . . . . . . . . . . 1E-283

1E-2 Electronic control fuel injection system (Common rail type) DTC: P0204 (Flash code 274) Open circuit in injection nozzle #4 drive system . . . . . . . . . . 1E-288 DTC: P0205 (Flash code 275) Open circuit in injection nozzle #5 drive system . . . . . . . . . . 1E-293 DTC: P0206 (Flash code 276) Open circuit in injection nozzle #6 drive system . . . . . . . . . . 1E-298 DTC: P0219 (Flash code 543) Overrun . . . . 1E-303 DTC: P0237 (Flash code 32) Boost sensor pressure fault (low voltage fault, open circuit) . . . . . . . 1E-305 DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault, short to power supply circuit, ground open circuit) . . . . . . . . . . . . . . . . . . . 1E-312 DTC: P0335 (Flash code 15) Crank sensor fault (no signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-319 DTC: P0336 (Flash code 15) Crank sensor fault (signal fault). . . . . . . . . . . . . . . . . . . . . . . . . . 1E-325 DTC: P0340 (Flash code 14) G sensor fault (no signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-331 DTC: P0341 (Flash code 14) G sensor fault (signal fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-337 DTC: P0380 (Flash code 66) Glow relay circuit fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-343 DTC: P0381 (Flash code 67) Glow plug lamp circuit fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-348 DTC: P0487 (Flash code 44) EGR position sensor fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-353 DTC: P0488 (Flash code 45) EGR valve control fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-359 DTC: P0522 (Flash code 294) Engine oil pressure sensor fault (low voltage fault, open circuit, ground short) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-365 DTC: P0523 (Flash code 295) Engine oil pressure sensor fault (high voltage fault, short to power supply, ground short) . . . . . . . . . . . . . . . . . . . . . . . . . 1E-371 DTC: P0601 (Flash code 53) ROM fault . . . . 1E-379 DTC: P0603 (Flash code 54) EEPROM fault 1E-381 DTC: P0606 (Flash code 51/52) CPU fault . . 1E-383 DTC: P0611 (Flash code 34) Charge circuit fault (bank 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-385 DTC: P0612 (Flash code 34) Charge circuit fault (bank 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-388 DTC: P0615 (Flash code 19) Starter cut relay circuit fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-391 DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-397 DTC: P1093 (Flash code 227) No pump pressure feed (2nd stage) . . . . . . . . . . . . . . . . . . . . . . 1E-402 DTC: P1094 (Flash code 226) No pump pressure feed (1st stage) . . . . . . . . . . . . . . . . . . . . . . . 1E-411 DTC: P1095 (Flash code 225) Pressure limiter open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-420 DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground short). . 1E-429 DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open circuit, short to power supply circuit) . . . . . . . . . . . . . . . . . . . 1E-437 DTC: P1173 (Flash code 542) Overheat . . . . 1E-444 DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-450 DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault . . . . . . . . . . . . . 1E-454 DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault . . . . . . . . . . . . . 1E-464 DTC: P1271 (Flash code 24) Accelerator sensor 1-2 comparison fault . . . . . . . . . . . . . . . . . . . . . . 1E-474 DTC: P1277 (Flash code 24) Accelerator sensor 1 fault (low voltage fault). . . . . . . . . . . . . . . . . . 1E-480 DTC: P1278 (Flash code 24) Accelerator sensor 1 fault (high voltage fault) . . . . . . . . . . . . . . . . . 1E-485 DTC: P1282 (Flash code 24) Accelerator sensor 2 fault (low voltage fault). . . . . . . . . . . . . . . . . . 1E-490 DTC: P1283 (Flash code 24) Accelerator sensor 2 fault (high voltage fault) . . . . . . . . . . . . . . . . . 1E-495 DTC: P1345 (Flash code 16) Cam sensor out of phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-500 DTC: P1625 (Flash code 416) Main relay fault1E-505 DTC: P1630 (Flash code 36) A/D conversion fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-512 DTC: P1631 (Flash code 55) Voltage fault in 5-V power supply 1 . . . . . . . . . . . . . . . . . . . . . . . 1E-514 DTC: P1632 (Flash code 55) Voltage fault in 5-V power supply 2 . . . . . . . . . . . . . . . . . . . . . . . 1E-517 DTC: P1633 (Flash code 55) Voltage fault in 5-V power supply 3 . . . . . . . . . . . . . . . . . . . . . . . 1E-520 DTC: P1634 (Flash code 55) Voltage fault in 5-V power supply 4 . . . . . . . . . . . . . . . . . . . . . . . 1E-523 DTC: P1635 (Flash code 55) Voltage fault in 5-V power supply 5 . . . . . . . . . . . . . . . . . . . . . . . 1E-526 DTC: U2104 (Flash code 84) CAN Bus fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-529 DTC: U2106 (Flash code 85) CAN timeout fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-534 List of trouble symptom . . . . . . . . . . . . . . . . . . 1E-539 Engine start failure. . . . . . . . . . . . . . . . . . . . . 1E-540 Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-544 Engine hunting, rough idling . . . . . . . . . . . . . 1E-548 Engine output shortage . . . . . . . . . . . . . . . . . 1E-552 Exhaust gas contains a lot of white smoke.. . 1E-557 Exhaust gas contains a lot of black smoke.. . 1E-560 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-563 Fuel consumption deteriorates. . . . . . . . . . . . 1E-565 Oil consumption deteriorates. . . . . . . . . . . . . 1E-568 Special tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-570 Difference by each machine manufacturer . . . . 1E-571 Hitachi Construction Machinery Co., Ltd. . . . 1E-571 About wiring diagrams . . . . . . . . . . . . . . . . . . 1E-574

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 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 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 ❍ ❍ 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

HITACHI ISUZU 6WG1 Engine Service Manual

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