Kawasaki ISUZU DIESEL ENGINE 4HK1 SHOP MANUAL 93207-00720 – PDF DOWNLOAD

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Kawasaki ISUZU DIESEL ENGINE 4HK1 SHOP MANUAL 93207-00720 – PDF DOWNLOAD

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Kawasaki ISUZU DIESEL ENGINE 4HK1 SHOP MANUAL 93207-00720 – PDF DOWNLOAD

Language :English
Pages :550
Downloadable : Yes
File Type : PDF

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Kawasaki ISUZU DIESEL ENGINE 4HK1 SHOP MANUAL 93207-00720 – PDF DOWNLOAD

Troubleshooting

Foreword

This manual contains the structure and the troubleshooting for electronic control fuel injection system (common rail type) in ISUZU DIESEL ENGINE 4HK1. All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication. Please note that the ISUZU DIESEL ENGINE 4HK1 is installed on the Kawasaki 65ZV-2 Wheel Loader. This manual was reproduced under the permission from the ISUZU MOTORS LIMITED

TABLE OF CONTENTS:

Kawasaki ISUZU DIESEL ENGINE 4HK1 SHOP MANUAL 93207-00720 – PDF DOWNLOAD

Troubleshooting

Control System 4
4HK1-24V Electronic Control Fuel Injection System (Common Rail Type) 4
How to Use This Manual 6
How to use this manual 6
Table of abbreviation 7
Conversion formula 8
About colors of wirings 9
About wiring diagrams 10
How to read trouble diagnosis section 11
Precautions on Service Work 13
Electrical system 13
Fuel injection system 13
Procedure of Trouble Diagnosis 15
About trouble diagnosis 15
Trouble diagnostic procedure 16
Interview 17
Pre-inspection 19
Trouble diagnosis 19
How to read DTC 20
Confirmation after repair 22
List of final check items 22
How to clear DTC 23
Trouble diagnosis with scan tool 24
Data reference value 30
How to Inspect Injector 43
How to use injector checker 43
Method to identify using non-contact infrared thermometer 47
Injector balance test (Tech2, EMPSIII) 48
How to Use Breaker Box 49
Breaker box inspection procedure 49
Engine Control System 52
Description of function and operation for engine control (common rail) system 52
Engine control module (ECM) 69
Engine component location diagram 71
Wiring diagram of engine control module (ECM) 85
Pin arrangement of engine control module (ECM) 86
Circuit diagram 90
Engine harness location105
Connector list110
List of Function Checks113
List of function checks113
OBD system check114
Diagnosis lamp illumination circuit system check116
Diagnosis lamp blinking circuit system check118
Scan tool power supply circuit system check (Tech2)121
Scan tool power supply circuit system check (EMPSIII)123
Scan tool communication circuit system check125
Starting circuit system check128
Starting system check133
Fuel system check136
Intake system check140
Exhaust system check141
EGR control system check142
QOS system check145
List of Diagnostic Trouble Codes150
List of diagnostic trouble codes150
DTC: P0087 (Flash code 227) Common rail low pressure fault (No pressure feed in supply pump)162
DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage)172
DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in supply pump)178
DTC: P0090 (Flash code 247) SCV drive system open circuit, +B short or ground short183
DTC: P0107 (Flash code 71) Barometric pressure sensor circuit input is low (open circuit or ground short)189
DTC: P0108 (Flash code 71) Barometric pressure sensor circuit input is high (+5V short)196
DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND short, short circuit)203
DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open circuit or short to power supply circuit)209
DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault, GND short, short circuit)216
DTC: P0118 (Flash code 23) Engine coolant temperature sensor input is high (open circuit or short to power supply)222
DTC: P0182 (Flash code 211) Fuel temperature sensor fault (low voltage fault, GND short)230
DTC: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open circuit or short to power supply circuit)236
DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short circuit)244
DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault)250
DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system256
DTC: P0202 (Flash code 272) Open circuit in injection nozzle #2 drive system261
DTC: P0203 (Flash code 273) Open circuit in injection nozzle #3 drive system266
DTC: P0204 (Flash code 274) Open circuit in injection nozzle #4 drive system271
DTC: P0219 (Flash code 543) Overrun276
DTC: P0237 (Flash code 32) Boost pressure sensor fault (low voltage fault, open circuit)278
DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault, short to power supply circuit, ground open circuit)285
DTC: P0335 (Flash code 15) Crank sensor fault (no signal)292
DTC: P0336 (Flash code 15) Crank sensor fault (signal fault)298
DTC: P0340 (Flash code 14) Cam sensor fault (no signal)303
DTC: P0341 (Flash code 14) Cam sensor fault (signal fault)309
DTC: P0380 (Flash code 66) Glow relay circuit fault315
DTC: P0381 (Flash code 67) Glow plug lamp circuit fault320
DTC: P0487 (Flash code 44) EGR position sensor fault325
DTC: P0488 (Flash code 45) EGR valve control fault331
DTC: P0522 (Flash code 294) Engine oil pressure sensor fault (low voltage fault, open circuit, ground short)337
DTC: P0523 (Flash code 294) Engine oil pressure sensor fault (high voltage fault, short to power supply, ground short)343
DTC: P0601 (Flash code 53) ROM fault350
DTC: P0603 (Flash code 54) EEPROM fault352
DTC: P0606 (Flash code 51) CPU fault354
DTC: P0606 (Flash code 52) CPU monitoring IC fault356
DTC: P0611 (Flash code 34) Charge circuit fault (bank 1)358
DTC: P0612 (Flash code 34) Charge circuit fault (bank 2)361
DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault364
DTC: P1093 (Flash code 227) No pump pressure feed369
DTC: P1095 (Flash code 225) Pressure limiter open380
DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground short)391
DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open circuit, short to power supply circuit)398
DTC: P1173 (Flash code 542) Overheat405
DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault410
DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault414
DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault422
DTC: P1271 (Flash code 24) Accelerator sensor 1-2 comparison fault430
DTC: P1277 (Flash code 24) Accelerator sensor 1 fault (low voltage fault)436
DTC: P1278 (Flash code 24) Accelerator sensor 1 fault (high voltage fault)441
DTC: P1282 (Flash code 24) Accelerator sensor 2 fault (low voltage fault)446
DTC: P1283 (Flash code 24) Accelerator sensor 2 fault (high voltage fault)451
DTC: P1293 (Flash code 221) Fuel intake pressure sensor fault (low voltage fault, open circuit, ground short)456
DTC: P1294 (Flash code 221) Fuel intake pressure sensor fault (high voltage fault, short to power supply, ground short)463
DTC: P1345 (Flash code 16) Cam sensor out of phase471
DTC: P1625 (Flash code 416) Main relay fault476
DTC: P1630 (Flash code 36) A/D conversion fault482
DTC: P1631 (Flash code 55) Voltage fault in 5-V power supply 1484
DTC: P1632 (Flash code 55) Voltage fault in 5 V power supply 2488
DTC: P1633 (Flash code 55) Voltage fault in 5-V power supply 3492
DTC: P1634 (Flash code 55) Voltage fault in 5-V power supply 4496
DTC: P1635 (Flash code 55) Voltage fault in 5-V power supply 5500
DTC: U2104 (Flash code 84) CAN Bus fault504
DTC: U2106 (Flash code 85) CAN timeout fault509
List of Trouble Symptom514
List of trouble symptom514
Engine start failure515
Engine stall523
Engine hunting, rough idling528
Engine output shortage533
Exhaust gas contains a lot of white smoke537
Exhaust gas contains a lot of black smoke540
Noise543
Fuel consumption deteriorates545
Oil consumption deteriorates548
Special Tool550
List of special tool550

S.M 2/2/25