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105 Trouble Shooting

 - EXAMPLE From Service Manual

Error Code set condition

1st step

• Rail pressure is more than 185MPa for 5 seconds

or more.

• Common rail pressure sensor voltage is 3.9 V or

more.

2nd step

• 1st stage is completed, and rail pressure is more

than 190MPa for 5 seconds or more.

• Common rail pressure sensor voltage is 4.0 V or

more.

Action taken when Error Code is set

• "ELEC. PROBLEM" is displayed.

Back-up mode

• L mode fixed.
• Limited injection amount 3 (multi-injection stopped)
• Target RP upper limit (80MPa)

Recovery from failure

• Recovery pattern 1.

Refer to “List of diagnostic trouble code” and “About
recovery from failure” error.

The conditions to clear the Error Code

• The error code is cleared from the current trouble

when the condition is either repaired or
disappeared.

Refer to "About recovery from failure".

Diagnostic aid

If the intermittent trouble is suspected, followings may
be the cause.

• Improper connection of harness connector
• Defective harness routing
• Worn harness cladding
• Wire disconnection inside harness cladding

Following inspections are necessary to detect these
causes.

• Improper connection of harness connector and

ECM connector

– Poor connection of terminal from connector
– Unmatched terminals are fitted.
– Damage of connector lock
– Poor contact between terminal and wire

• Damaged harness

– Visually check the harness for damage.
– Check the relevant items while moving the

connector and the harness which are related to
the sensor.

TSHK0043

Common rail 

presure

200 MPa

T

T

T>1sec=P1095

T>5sec=P0088

190 MPa
185 MPa

Step

Action

Value

YES

NO

1

Check the error code 0088.

—

Go to Step 2.

—

2

1.

Start the engine.

2.

Check the Error Code.

3.

Are the fuel-related parts only just
replaced?
Air bleeding may not be performed
sufficiently after replacing fuel-related
parts. Bleed air again. Check the Error
Code after bleeding air.

Is any of the 0088, 0192, 0193, or 1635
detected?

—

Go to the relevant 

Error Code 

detected.

Go to Step 3.

Содержание 4HK-1

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

Страница 2: ...2 Table Of Contents...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 15: ...15...

Страница 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...

Страница 17: ...17...

Страница 18: ...18...

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

Страница 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...

Страница 21: ...21...

Страница 22: ...22...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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