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Isuzu 4HK-1 Manual Download Page 38

Engine Control System 70

H95

Terminal 

Number

1

—

2

OS

−

INJ6 signal

3

Injector power supply 2

4

Injector power supply 1

5

—

6

OS

−

INJ4 signal

7

OS

−

INJ2 signal

8

—

TSWG0041

In cylinder head

H95
(Male connector on ECM side)

H95
(Female connector on injector side)

H94
(Male connector on ECM side)

H94
(Female connector 
on injector side)

Summary of Contents for 4HK-1

Page 1: ...1 Isuzu 4HK 1 and 6HK 1 ENGINE FUEL SYSTEM CE APPLICATIONS Revised 8 29 06 Form Number 5137...

Page 2: ...2 Table Of Contents...

Page 3: ...s the basic injection amount based on the signals from throttle position sensor boost pressure sensor crank position sensor cam position sensor etc It regulates the opening closing period of common ra...

Page 4: ...installed on the fuel supply pump The fuel temperature sensor measures the temperature of the drain fuel from the pump When the fuel temperature sensor is cold the sensor resistance is high When the f...

Page 5: ...1 Ignition Wire 2 Positive Wires 6 Ground Wires CAN Data Bus Connector Throttle Idle Up Down Work Modes Breaker Mode Tach Instrumentation Faults Engine Harness 81 Pin Connector A0 Engine Harness 40 P...

Page 6: ...ne reference hole on the camshaft gear flange surface on the 6HK 1 Engine The camshaft position sensor indicates the rotational position of the camshaft to the ECM The CMP signal input determines the...

Page 7: ...1 Ignition Wire 2 Positive Wires 6 Ground Wires CAN Data Bus Connector Throttle Idle Up Down Work Modes Breaker Mode Tach Instrumentation Faults Engine Harness 81 Pin Connector A0 Engine Harness 40 P...

Page 8: ...ine just below and forward of the high pressure injection pump An engine emergency stop signal is sent from the machine controller to the engine controller The machine controller receives an engine st...

Page 9: ...1 Ignition Wire 2 Positive Wires 6 Ground Wires CAN Data Bus Connector Throttle Idle Up Down Work Modes Breaker Mode Tach Instrumentation Faults Engine Harness 81 Pin Connector A0 Engine Harness 40 P...

Page 10: ...the glow relay K2 After a certain time has elapsed the ECM will turn the glow relay to OFF Also after glow function allows to stabilize idling immediately after starting Outputs from 40 pin engine ha...

Page 11: ...1 Ignition Wire 2 Positive Wires 6 Ground Wires CAN Data Bus Connector Throttle Idle Up Down Work Modes Breaker Mode Tach Instrumentation Faults Engine Harness 81 Pin Connector A0 Engine Harness 40 P...

Page 12: ...sic injection amount and timing based on the signals from throttle position sensor boost pressure sensor crankshaft CKP sensor camshaft CMP sensor etc The timing of the injection is controlled by when...

Page 13: ...1 Ignition Wire 2 Positive Wires 6 Ground Wires CAN Data Bus Connector Throttle Idle Up Down Work Modes Breaker Mode Tach Instrumentation Faults Engine Harness 81 Pin Connector A0 Engine Harness 40 P...

Page 14: ...he high pressure pump Once these conditions are met install the injection pump The high pressure injection pump has a shaft driven gerotor feed charge pump which provides fuel to the pump pressure con...

Page 15: ...15...

Page 16: ...flow when the fuel pressure inside the common rail becomes about 0 6 MPa 87 psi High pressure fuel from the common rail is available to the inlet of all of the injectors A high pressure line connects...

Page 17: ...17...

Page 18: ...18...

Page 19: ...19 Isuzu 4HK 1 and 6HK 1 Engine Sensor Locations...

Page 20: ...ntrol the amount of EGR The cooling system EGR cooler equipped on the EGR gas passage allows to cool down high temperature EGR gas and mix it with new air to lower the combustion temperature further r...

Page 21: ...21...

Page 22: ...22...

Page 23: ...eave as it is OFF for 10 seconds Failure to perform the EGR valve position learning may result in detection of Error Code for EGR About ECM power off The power supply inside the ECM does not go off fo...

Page 24: ...Engine Control System 56 Senser and actuator Refer at last page About wiring diagrams...

Page 25: ...Control System Circuit diagram Refer to Wiring diagrams for a way to read the diagram Main relay circuit TSWG0027 FUSE B 20A 20A 5 2 B B 40 21 E 57 E 57 E 57 E 57 Main relay Battery Engine control mo...

Page 26: ...System 58 Starter for safety relay glow circuit TSWG0068 Glow relay control 10 E 57 B B C Safety relay Battery Generator Starter 1 H 1 1 H 22 5 B W Glow plug Glow relay 65A 30A B C L R E S Engine cont...

Page 27: ...GND DLC circuits TSHK0013 CAN HIGH CAN LOW 37 E 57 4 E 57 3 E 57 1 E 57 43 E 57 62 E 57 81 E 57 DLC 18 E 57 CAN HIGH CAN LOW 38 E 57 7 FL 150 KWP2000 52 E 57 1 FL 150 4 FL 150 5 FL 150 Shovel controll...

Page 28: ...6 2 H 95 2 H 95 3 E 33 11 0 75 G B 4 H 95 4 H 95 1 25 R Injector Cylinder No 6 2 1 E 37 Injector Cylinder No 4 2 1 E 33 Cylinder No 2 Injector Cylinder No 2 Feedback 114 E 56 7 H 94 7 H 94 3 2 1 E 29...

Page 29: ...61 Engine Control System SCV circuit TSHK0016 97 E 56 89 E 56 105 E 56 113 E 56 SCV 0 75 R W 0 75 R B 2 1 B Engine contorol module ECM 2 3 H 6 H 6 E 161 E 161...

Page 30: ...B Y 0 75 B Y 0 75 L Y 0 75 W B 5V 84 E 56 5V 5V 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 CKP HIGH signal CKP sensor CKP LOW signal Fuel temperat...

Page 31: ...34 91 E 56 E 56 Boost pressure sensor signal Boost pressure sensor 95 E 56 109 3 E 75 8 H 20 16 H 20 2 E 75 0 75 R W 0 75 R L 0 75 L 1 E 75 17 1 5V 5V Boost temperature sensor signal Boost temperature...

Page 32: ...1 4 E 112 87 E 56 0 75 W 0 75 W 0 75 G 1 12 E 80 90 E 56 3 E 113 2 E 113 13 0 75 B 0 75 Br 0 75 W R 98 E 56 2 5 E 112 3 E 112 0 75 B W 1 E 113 6 82 E 56 100 E 56 U H 20 H 20 H 20 H 20 H 20 H 8 H 8 H...

Page 33: ...65 Engine Control System Memory clear switch engine stop switch circuit TSWG0038 47 E 57 control module ECM 32 E 57 52 E 57 CAN HIGH CN 6 2I 43 CN 3 CAN LOW 37 E 57 18 E 57 CAN HIGH CAN LOW...

Page 34: ...This page Is Intentionally Left Blank...

Page 35: ...4 1 1 5 V W Y B R B R W B W V W B R L L W B r 0 5 0 7 5 0 5 Y 0 5 0 7 5 0 5 L Y B Y L W B 0 7 5 0 7 5 0 5 0 7 5 R L 0 7 5 0 5 0 7 5 0 7 5 0 5 0 7 5 0 7 5 2 6 7 8 9 1 0 11 1 2 13 1 4 1 5 1 6 17 1 8 1 9...

Page 36: ...r V 4 EGR hall sensor U 5 EGR GND 6 EGR motor W 7 EGR motor V 8 EGR motor U Terminal Number 1 ECT GND 2 ECT 3 ECT meter Terminal Number 1 Fuel temperature sensor GND 2 Fuel temperature sensor Terminal...

Page 37: ...l 9 10 11 OS INJ6 signal 12 OS INJ5 signal Terminal Number 1 CKP 2 CKP GND 3 CKP shield 4 CMP 5 CMP GND 6 CMP shield 7 ECT 8 Boost pressure sensor Vcc 9 Engine oil pressure sensor Vcc 10 Engine oil pr...

Page 38: ...gnal 3 Injector power supply 2 4 Injector power supply 1 5 6 OS INJ4 signal 7 OS INJ2 signal 8 TSWG0041 In cylinder head H95 Male connector on ECM side H95 Female connector on injector side H94 Male c...

Page 39: ...er E 29 2 injector Silver E 31 3 injector Silver E 33 4 injector Silver E 35 5 injector Silver E 37 6 injector Silver E 56 Gray E 57 Gray E 75 E 76 Black E 80 Black E 90 Blue E 93 Gray E 98 Black E 11...

Page 40: ...63 Gray E 164 FB 124 Black FL 150 FL 269 No Connector Face 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 016 500 1 2 3 003 502 H1 Black H 6 Gray H 6 Gray H 8 Black H 8 Black H 12 Gray H 12 Gray H 20 No Conne...

Page 41: ...side Gray H 94 ECM side Gray H 94 Injector side Gray H 94 Injector side Gray H 95 ECM side Gray No Connector Face 020 501 4 3 2 1 8 7 6 5 12 11 10 9 16 15 14 13 20 19 18 17 H 95 ECM side Gray H 95 In...

Page 42: ...This page Is Intentionally Left Blank...

Page 43: ...MPLE From Service Manual Error Code 0088 Common rail pressure is abnormally high 1st or 2nd stage Name 1 Common rail 2 Fuel filter 3 Electromagnetic Pump 4 Pre filter 5 Fuel tank 6 Supply pump 7 Injec...

Page 44: ...ing Engine blow up fault Black smoke emitted Excessive output possible Preconditions when Error Code is set 1st step Key switch input voltage is 18V or more Error Code 0088 0192 0193 or 1635 is not de...

Page 45: ...pected followings may be the cause Improper connection of harness connector Defective harness routing Worn harness cladding Wire disconnection inside harness cladding Following inspections are necessa...

Page 46: ...2 Check the Error Code Is the trouble detected Go to Step 5 Go to Step 6 5 Replace the supply pump Note For work procedure refer to Engine section in the service manual Is the procedure completed Go t...

Page 47: ...oting EXAMPLE From Service Manual About common rail pressure sensor Name 1 Sensor ground 2 Sensor signal 3 Sensor power supply Characteristics of common rail pressure sensor 1 2 3 TSWG0055 4 2 1 0 200...

Page 48: ...able 6 380002728 EMPS EST RS232 Null Modem Cable The Additional Tools screen provides a button linking the Electronic Service Tool to Engine Diagnostic Tool Isuzu EMPS Start the Engine Download Tool I...

Page 49: ...as the manufacturer for all CNH applications Preliminary ELECTRONIC SERVICE TOOL EST Engine Module Programming System EMPS Summary Selecting an EMPS Process Select an EMPS operation from the Process...

Page 50: ...This page Is Intentionally Left Blank...

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