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Isuzu 4HK-1 Manual
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Isuzu 4HK-1 Manual

Isuzu 4HK-1 Manual

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Isuzu
4HK-1 and 6HK-1
ENGINE
FUEL SYSTEM
CE APPLICATIONS
Revised 8/29/06
Form Number 5137
1

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Summary of Contents for Isuzu 4HK-1

  • Page 1 Isuzu 4HK-1 and 6HK-1 ENGINE FUEL SYSTEM CE APPLICATIONS Revised 8/29/06 Form Number 5137...
  • Page 2 Table Of Contents...
  • Page 3 These engines also use an air to air aftercooling intake air system. The air to air intake system ports pressurized air flow between the turbocharger and the intake manifold through an air to air heat exchanger in front of the radiator. The 4HK-1 model has a displacement of 317 cubic inches (in ) or 5193 cubic centimeters (cc).
  • Page 4 Isuzu 4HK-1 and 6HK-1 Engine Overview The electronic control system for the Isuzu 4HK-1 and 6HK-1 Engines use input information from a number of sensors and from the Excavator controller to determine the quantity and timing of the fuel delivery to the engine.
  • Page 5 Isuzu 6HK1 Common Rail Engine Fuel System Common Fuel Temp Coolant Intake Air Boost Temp Barometric ENG Oil Engine Stop Rail Fuel PSI Sensor Temperature Temp. Sensor Sensor AMB PSI Switch Sensor Sensor Sensor Sensor Boost PSI Crankshaft Camshaft Sensor...
  • Page 6 90° on the gear and one reference hole) on the camshaft gear flange surface on the 4HK-1 Engine. Seven through holes (six holes arranged equally every 60° on the gear and one reference hole) on the camshaft gear flange surface on the 6HK-1 Engine.
  • Page 7 Isuzu 6HK1 Common Rail Engine Fuel System Common Fuel Temp Coolant Intake Air Boost Temp Barometric ENG Oil Engine Stop Rail Fuel PSI Sensor Temperature Temp. Sensor Sensor AMB PSI Switch Sensor Sensor Sensor Sensor Boost PSI Crankshaft Camshaft Sensor...
  • Page 8 Isuzu 4HK-1 and 6HK-1 Engine Overview (continued) Inputs to 81 pin engine harness connector: • The 2 wire intake air temperature (IAT) sensor is installed on intake air tube and detects the temperature of intake air for optimum fuel injection control.
  • Page 9 Isuzu 6HK1 Common Rail Engine Fuel System Common Fuel Temp Coolant Intake Air Boost Temp Barometric ENG Oil Engine Stop Rail Fuel PSI Sensor Temperature Temp. Sensor Sensor AMB PSI Switch Sensor Sensor Sensor Sensor Boost PSI Crankshaft Camshaft Sensor...
  • Page 10 Isuzu 4HK-1 and 6HK-1 Engine Overview (continued) Inputs to 81 pin engine harness connector: (continued) • The CAN (Controller Area Network) Data Bus Connector transmits communication between the engine controller and the Excavator controller. This connector transmits throttle, idle up/down, work mode, breaker mode, tachometer, instrumentation and fault code information.
  • Page 11 Isuzu 6HK1 Common Rail Engine Fuel System Common Fuel Temp Coolant Intake Air Boost Temp Barometric ENG Oil Engine Stop Rail Fuel PSI Sensor Temperature Temp. Sensor Sensor AMB PSI Switch Sensor Sensor Sensor Sensor Boost PSI Crankshaft Camshaft Sensor...
  • Page 12 Isuzu 4HK-1 and 6HK-1 Engine Overview (continued) Outputs from 40 pin engine harness connector: (continued) • The injectors are controlled by the engine control module (ECM). The ECM sends a common power supply to injectors 1, 3 and 5. The ECM also sends a common power supply to injectors 2, 4 and 6.
  • Page 13 Isuzu 6HK1 Common Rail Engine Fuel System Common Fuel Temp Coolant Intake Air Boost Temp Barometric ENG Oil Engine Stop Rail Fuel PSI Sensor Temperature Temp. Sensor Sensor AMB PSI Switch Sensor Sensor Sensor Sensor Boost PSI Crankshaft Camshaft Sensor...
  • Page 14 Isuzu 4HK-1 and 6HK-1 Engine Fuel Schematic Overview Fuel System Hydraulic Function Fuel comes from the tank and typically will go through a prefilter assembly. From the prefilter, the fuel then flows to an electric fuel pump, located in the hydraulic pump compartment.
  • Page 16 Isuzu 4HK-1 and 6HK-1 Engine Fuel Schematic Overview The common rail system stores high pressure fuel between the supply pump and the injectors. The common rail also serves as an accumulator to dampen the fuel pulsations from the pump. Flow dampers are located at the outlet of the common rail to the lines to the injectors.
  • Page 19 Isuzu 4HK-1 and 6HK-1 Engine Sensor Locations...
  • Page 20 Exhaust gas Recirculation (EGR) System Exhaust Gas Recirculation system is abbreviated to EGR system. It recirculates part of exhaust gas into intake manifold to mix an inert gas with intake air. This leads to lower the combustion temperature to limit emissions of nitrogen oxide (NOx). It controls amount of EGR by opening/closing the EGR valve installed between exhaust manifold and intake manifold.

  • Page 23: Engine Control System

    Engine Control System 42 Installation of ECM Install the ECM in the reverse order of removal. EGR valve position learning is required after replacing the ECM. 1. Turn the key switch to “ON”. 2. Turn the key switch to “OFF”. 3.
  • Page 24 Engine Control System 56 Senser and actuator *Refer at last page.(About wiring diagrams)
  • Page 25 57 Engine Control System Circuit diagram (Refer to “Wiring diagrams” for a way to read the diagram.) Main relay circuit TSWG0027...
  • Page 26 Engine Control System 58 Starter for safety relay, glow circuit TSWG0068...
  • Page 27 59 Engine Control System CAN, GND, DLC circuits TSHK0013...
  • Page 28 Engine Control System 60 Injector circuit TSWG0031...
  • Page 29 61 Engine Control System SCV circuit TSHK0016...
  • Page 30 Engine Control System 62 CKP sensor, fuel temperature sensor, engine coolant temperature sensor, engine oil pressure sensor circuit TSHK0017...
  • Page 31 63 Engine Control System Boost temperature sensor, boost pressure sensor circuit TSWG0034...
  • Page 32 Engine Control System 64 CMP sensor, common rail pressure sensor, EGR circuit TSHK0018...
  • Page 33 65 Engine Control System Memory clear switch, engine stop switch circuit TSWG0038...
  • Page 34 This page Is Intentionally Left Blank.
  • Page 35 67 Engine Control System TSHK0035...
  • Page 36 Engine Control System 68 Terminal Terminal Number Number Boost pressure sensor GND CKP + Boost pressure sensor Vout CKP GND Boost pressure sensor Vcc E112 Terminal Number Terminal Number CMP shield Engine oil pressure sensor GND CMP GND Engine oil pressure sensor Vout CMP + Engine oil pressure sensor Vcc E113...
  • Page 37 69 Engine Control System Terminal Terminal Number Number SCV−Lo CKP + SCV−Hi CKP GND Fuel temperature sensor + CKP shield ECT meter CMP + — CMP GND Overheating switch CMP shield ECT + Boost pressure sensor Vcc Terminal Engine oil pressure sensor Vcc Number Engine oil pressure sensor Vout EGR hall sensor U...
  • Page 38 Engine Control System 70 Terminal Number — OS−INJ6 signal Injector power supply 2 Injector power supply 1 — OS−INJ4 signal OS−INJ2 signal — (Female connector on injector side) In cylinder head (Female connector on injector side) (Male connector on ECM side) (Male connector on ECM side) TSWG0041...
  • Page 39 71 Engine Control System Connector list Connector Face Connector Face E-27 E-75 003-501 #1 injector (Silver) E-29 E-76 003-501 #2 injector (Silver) (Black) E-31 E-80 #3 injector (Silver) (Black) E-33 E-90 003-500 #4 injector (Silver) (Blue) E-35 E-93 #5 injector (Silver) (Gray) E-37 E-98...
  • Page 40 Engine Control System 72 Connector Face Connector Face E-114 (Black) (Black) E-161 (Brown) (Gray) E-162 (Dark gray) (Gray) E-163 (Gray) (Black) E-164 (Black) FB-124 H-12 (Black) (Gray) FL-150 H-12 016-500 (Gray) 9 10 11 12 FL-269 H-20 13 14 15 16 17 18 19 20 020-500 003-502...
  • Page 41 73 Engine Control System Connector Face Connector Face H-95 12 11 10 9 H-20 (ECM 16 15 14 13 side) 20 19 18 17 020-501 (Gray) H-95 (Injector side) (White) (Gray) H-95 (Injector side) (White) (Gray) H-94 (ECM side) (Gray) H-94 (ECM side)
  • Page 42 This page Is Intentionally Left Blank.
  • Page 43 103 Trouble Shooting - EXAMPLE From Service Manual Error Code: 0088 Common rail pressure is abnormally high (1st or 2nd stage). TSHK0041 Name 1. Common rail 5. Fuel tank 2. Fuel filter 6. Supply pump 3. Electromagnetic Pump 7. Injector 4.

  • Page 44: Trouble Shooting 104

    Trouble Shooting 104 Engine control module (ECM) CMP sensor EGR position EGR position EGR position Common rail pressure signal sensor signal sensor signal sensor signal sensor signal 99 E-56 98 E-56 E-56 E-56 E-56 E-56 E-56 E-56 E-56 E-56 E-56 E-56 E-56 H-20...
  • Page 45 105 Trouble Shooting - EXAMPLE From Service Manual Error Code set condition Back-up mode 1st step • L mode fixed. • Rail pressure is more than 185MPa for 5 seconds • Limited injection amount 3 (multi-injection stopped) or more. • Target RP upper limit (80MPa) •...

  • Page 46: Trouble Shooting 106

    Trouble Shooting 106 Step Action Value Check the fuel return pipe between the supply pump and the fuel tank for breakage, twist, etc. Check for clogging or twisting in the vent hose of the fuel tank. — Check for foreign matter in the fuel tank. If the trouble is detected, repair as required.
  • Page 47 107 Trouble Shooting - EXAMPLE From Service Manual About common rail pressure sensor TSWG0055 Name 1. Sensor ground 2. Sensor signal 3. Sensor power supply Characteristics of common rail pressure sensor (MPa) TSWG0201...
  • Page 48 5. 380002726 EMPS/EST ECM Cable 6. 380002728 EMPS/EST RS232 Null Modem Cable Start the Engine Download Tool - Isuzu EMPS The Additional Tools screen provides a button linking the Electronic Service Tool to: • Engine Diagnostic Tool - Isuzu EMPS...

  • Page 49: Process Menu

    Preliminary ELECTRONIC SERVICE TOOL (EST) Engine Module Programming System (EMPS) - Summary Selecting an EMPS Process Process Menu Select an EMPS operation from the Process Menu Process Menu. • ECM Reflash - Select when the ECM control program is suspected to have ECM Reflash damaged/corrupted files.
  • Page 50 This page Is Intentionally Left Blank.

This manual is also suitable for:

6hk-1