Мануал исудзу эльф 4hk1

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  Isuzu 4HK-1 and 6HK-1 ENGINE FUEL SYSTEM CE APPLICATIONS Revised 8/29/06 Form Number 5137…
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  Table Of Contents…
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  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).
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  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.
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  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…
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  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.
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  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…
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  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.
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  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…
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  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.
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  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…
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  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.
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  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…
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  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.
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  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.
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  Isuzu 4HK-1 and 6HK-1 Engine Sensor Locations…
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  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.

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  Engine Control System 56 Senser and actuator *Refer at last page.(About wiring diagrams)
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  57 Engine Control System Circuit diagram (Refer to “Wiring diagrams” for a way to read the diagram.) Main relay circuit TSWG0027…
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  Engine Control System 58 Starter for safety relay, glow circuit TSWG0068…
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  59 Engine Control System CAN, GND, DLC circuits TSHK0013…
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  Engine Control System 60 Injector circuit TSWG0031…
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  61 Engine Control System SCV circuit TSHK0016…
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  Engine Control System 62 CKP sensor, fuel temperature sensor, engine coolant temperature sensor, engine oil pressure sensor circuit TSHK0017…
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  63 Engine Control System Boost temperature sensor, boost pressure sensor circuit TSWG0034…
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  Engine Control System 64 CMP sensor, common rail pressure sensor, EGR circuit TSHK0018…
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  65 Engine Control System Memory clear switch, engine stop switch circuit TSWG0038…
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  67 Engine Control System TSHK0035…
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  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…
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  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…
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  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…
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  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…
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  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…
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  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)
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  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.

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  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…

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  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) •…

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  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.

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  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…
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  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…

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  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.

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Isuzu

4HK-1 and 6HK-1

ENGINE

FUEL SYSTEM

CE APPLICATIONS

Isuzu 4HK-1 and 6HK-1 Engine Overview

The Tier III CX330 Excavators are equipped with an Isuzu 6HK-1 model common rail fuel system Engine. The Isuzu 4HK-1 model will be used in at least one other

Excavator model. These engines have 4 valves per cylinder, operated by a single overhead cam to optimize air flow, fuel economy and emissions. The injector is now located at the center of the piston under the valve cover. The fuel system is now totally electronically controlled. These engines use an water cooled Exhaust Gas Recirculation, (EGR) system, which allows a controlled amount of exhaust gas to return back to the intake. This EGR system is used to reduce the emissions level of the engine. 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 (in3) or 5193 cubic centimeters (cc). The 6HK-1 model has a displacement of 475 cubic inches (in3) or 7790cubic centimeters (cc).

The ECM calculates 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 rail pressure control valve and the electric activation of each injector according to the common rail pressure, engine coolant temperature, etc. at this time, to correct the optimum injection timing and injection amount.

At engine start (after the key switch is turned to the START position to start the engine, and until the return of the key switch to the ON position), the fuel injection quantity is controlled based on information from the start signal, engine speed, and engine coolant temperature. At low temperature, the fuel injection quantity increases. When the engine starts completely, this boosted quantity mode at starting is cancelled and normal running mode is restored.

The ECM calculates the current altitude based on the barometric pressure sensor signal. It corrects the fuel flow according to the altitude etc. at this time.

The Excavator machine controller communicates with the engine controller (ECM) via the CAN Data Bus system to control engine speed, return to idle command, activate the work modes and also to set the engine speed required for the breaker mode.

Engine Performance Needs

1.Air

2.Compression

3.Fuel

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.

The engine control module (ECM), is located on the inside rear of the cab. The ECM has two connectors, one an 81 pin and one 40 pin, for inputs and outputs. The engine control module requires downloading of control software to give it the ability to control all functions.

Inputs to 40 pin engine harness connector:

•The common rail fuel pressure sensor has 3 wires and is located on the common rail. This sensor detects the fuel pressure in the common rail, converts the pressure into a voltage signal, and sends the signal to the ECM. Higher common rail pressure provides higher fuel pressure sensor voltage while lower pressure provides lower fuel pressure sensor voltage.

•The 2 wire variable resistor fuel temperature sensor is 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 fuel temperature increases, the sensor resistance decreases. With high sensor resistance, the ECM detects a high voltage on the signal circuit. With lower sensor resistance, the ECM detects a lower voltage on the signal circuit.

•The 2 wire engine coolant temperature sensor is located on the thermostat housing at the right front corner of the engine. The coolant sensor’s temperature detection component uses a thermistor. A 5 volt reference voltage is applied at all times to the sensor from the ECM. The ECM detects a voltage change due to a resistance value change in the sensor caused by the coolant temperature change.

Isuzu 4HK-1 and 6HK-1 Engine Overview (continued)

Inputs to 40 pin engine harness connector(continued):

•The 2 wire crankshaft position sensor (CKP) is located on the flywheel housing at the left rear corner of the engine. The CKP sensor detects 45 projections equally spaced every 7.5° around the flywheel periphery. There is also a space (equal to 3 projections) to act as a top dead center (TDC) reference signal for the engine control module (ECM). With these 45 pulses and the TDC reference signal, the ECM calculates the engine speed and exact position of the crankshaft.

•The 2 wire camshaft position sensor (CMP) is located on the cylinder head at the rear of the camshaft gear. The camshaft position sensor detects a total of the number of the cylinders in the engine plus an extra one. The extra hole indicates the top dead center position of number 1 cylinder. Five through holes (four holes arranged equally every 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. The camshaft position sensor indicates the rotational position of the camshaft to the ECM. The CMP signal input, determines the crank angle and the ECM can use it to control fuel injection and calculate the engine speed. The crankshaft position sensor (CKP) typically controls these functions, however it is done by CMP sensor if the CKP sensor is faulty.

Diagnostic aid

If there is relevant Error Code to the crankshaft (CKP) sensor and Camshaft (CMP) sensor, the engine will not start until memory clear is performed.

If an intermittent trouble is suspected, the following may be the cause:

•Improper connection of harness connector

•Defective harness routing

•Worn harness cover

•Wire disconnection inside harness cover

•The 3 wire boost pressure sensor is located in the piping to the intake manifold of the engine. The sensor converts the boost pressure into the voltage signal and sends it to engine control module (ECM). The ECM should detect a higher signal voltage at a high boost pressure.

•The 4 wire Exhaust Gas Recirculation (EGR) position sensor is installed in EGR valve and detects the valve lift amount of EGR.

Note:

Do not disassemble the EGR position sensor. If it is faulty, replace it as EGR valve assembly.

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.

•The 2 wire boost temperature sensor is installed onto the EGR valve on the upstream side of intake manifold. The sensor is a thermistor type. The resistance in the sensor changes as the temperature changes. When the intake temperature sensor is cold, the sensor resistance is high. When the intake temperature increases, the sensor resistance decreases. With high sensor resistance, the ECM detects a high voltage on the signal circuit. With lower sensor resistance, the ECM detects a lower voltage on the signal circuit.

•The 3 wire barometric pressure sensor is installed on the machine and converts the ambient barometric pressure into a voltage signal. The ECM calculates barometric pressure by this voltage signal and corrects the fuel injection amount (high-altitude correction) as the machine works at a higher elevation.

•The 3 wire engine oil pressure sensor is located on the left side of the engine 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 stop signal from the stop switch located in the instrument cluster.

•As the engine is started (after the key switch is turned to the START position to start the engine, and until the return of the key switch to the ON position), optimum fuel injection quantity is delivered based on information from the starter switch signal, engine speed, and the engine coolant temperature sensor (ECT). At low temperature, the fuel injection quantity increases. As the engine starts completely, this boosted quantity mode at starting is cancelled and normal running mode is restored.

•Power Supply – Ignition power is sent to the engine control module (ECM) any time that the key switch is in the run position. When the ignition signal is present, the ECM activates the main relay. Once the Main Relay (K33 on machine schematic) is activated, battery power is fed to the ECM through the relay normally open (NO) contact to pins number 2 and 6. When the key switch is turned to the off position, the ECM continues to hold the main relay activated for a period of time to allow the ECM to power down safely. This delay is about 10 seconds. The ECM has six ground connections in total.

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.

•The memory clear (X23), diagnostic switch (X24) and data link (X4) connectors are not used with the Case Electronic Service Tool (EST) diagnostic system. They are required when using the Tech 2 Diagnostic Tool.

Outputs from 81 pin engine harness connector:

•When the ignition signal is present from the keyswitch, the ECM activates the main relay. Once the Main Relay (K33 on machine schematic) is activated, battery power is fed to the ECM through the relay normally open (NO) contacts to pins number 2 and 6. When the key switch is turned to the off position, the ECM continues to hold the main relay activated for a period of time to allow the ECM to power down safely. This delay is about 10 seconds.

•The glow control relay system consists of the ECM, glow relay, glow plug. When the key switch is turned ON with low engine coolant temperatures, the ECM determines the glow time and operates 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 harness connector:

•The engine driven high pressure injection pump pressurizes fuel to feed to the common rail. The injection pump has a suction control valve (SCV), and a fuel temperature (FT) sensor. The suction control valve (SCV) is installed onto high pressure pump section and controls supply of fuel (discharge amount) to common rail. The engine control module (ECM) regulates period of electrical activation time of the SCV to regulate the fuel discharge amount.

Do not replace the SCV. If it is faulty, replace it as supply pump ASM.

•The exhaust gas recirculation (EGR) system recirculates a part of the exhaust gas to the engine intake to reduce the combustion temperature inside the cylinders to reduce NOx (nitrogen oxides) in the exhaust gas. The EGR valve opening is calculated according to the engine coolant temperature (ECT), the engine speed, and the target fuel injection quantity. The EGR motor is the brushless DC motor, and is driven by three phases. The ECM drives the EGR motor through the EGR motor drive circuits U, V, and W. The motor rotates with a combination of the threephase signals. The ECM sets the Error Code when the EGR motor drive duty is high and the difference between the target EGR position and actual EGR position is large.

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. The ECM fires the injectors by controlling the ground of the individual injectors. The ECM calculates the basic 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 the injector activates. The fuel quantity delivered is based upon the amount of time that the injector is open and also the pressure supplied by the common rail. To improve combustion in cylinders, the system injects a little fuel (preinjection or pilot injection) and ignites it at the beginning of the cycle. A second injection (main injection) delivers the fuel required deliver the horsepower needed.

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. The 24 volt electric fuel pump is powered directly by the battery relay, through the 65 amp fuse (F23) and the 10 amp electrical fuel pump fuse (F8) in the fuse box. The electric fuel pump then sends the fuel through the fuel filter also located hydraulic pump compartment to the inlet port of the high pressure injection pump.

The high pressure injection pump is mounted at the left rear of the engine. This pump needs to be timed to the engine. To install the pump, bring the engine to TDC and then align the mark on the pump drive gear to the mark on the front face of the 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 control valve (Suction Control Valve SCV). The gerotor pump outlet pressure is controlled by the regulation valve to provide a constant pressure at the inlet of the high pressure pumping pistons. The high pressurepump PSI regulator (SCV), located in the injection pump, controls the flow output of the high pressure pump. The high pressure pump supplies the quantity of fuel to the common rail required to maintain the pressure dictated by the engine control unit (ECM). This assures that only the required amount of fuel is pressurized, improving energy efficiency and limiting heating of fuel in the system. The common rail pressure will range from 3625 to 29,000 PSI (25 to 200 MPa). Excess flow from the feed pump and internal leakage from the injection pump returns to the tank. The fuel temperature sensor (FT) monitors the temperature of this fuel.