ISUZU MOTORS LIMITED Off-highway Powertrain Operation Dept. Planning & Service Group
HITACHI CONSTRUCTION MACHINERY CO.,Ltd Technical Training Center April 2007
Table of contents
1. Differences between Tier2 engine and Tier3 engine. Differences between Tier2 engine and Tier3 engine. •‡ @
•@ •@
Off Road Emission Regulation Engine Specifications Engine Layout /Main Parts Engine Layout /Sensors •@ A• ‡ @Out @Out Line of Common Rail System Common Rail System •@ Comparison with Conventional System •@ ‡B• B@System @ • System Component @ • a@ • ECM@ • •@ •@ b•@SUPP SUPPLY LY PUMP PUMP •@ •@ c CO COMM MMON ON RAIL RAIL•@ • @ • •@ •@d•@INJECTOR•@ •@ @ • e•@HARNES HAR NESS S INJECTOR INJE CTOR @ • f SENSORS g COOLED•@EGR 2. 3. 4. •@
Maintenance Schedule Introduction of SST Trouble Shooting ‡ @ • Trouble Shooting Procedure
A• ‡ @How @How to use Trouble Shooting Manual 5. DTC code ‡ @ • DTC code
A• •@ ‡@ •@ B• ‡ B@ • •C• @ ‡ C@ •
Scan Tool EMPS How to use scan tool@ •
j 6. Point to notice notice on service service i• Parts replace procedure• 7. Trouble Shooting on actual machine
Tier-3 Engine major specification and Maintenance point 1.High pressure fuel injection control by common rail system. Prohibit teardown and re-adjustment of injector. Prohibit re-use of injector pipe and high pressure fuel pipe. Must be keep ISUZU fuel requirement. Keep observe strictly the maintenance schedule. 2.Electronic control module. notice : A battery cable must be disconnect at the time of welding work for ECM protection. 3.Cooled EGR Must be keep ISUZU fuel requirement. Must be keep ISUZU Engine oil requirement and maintenance. Observe engine strictly of Maintenance.
Off-Road Future Emission Regulation CLASS EPA
EC
JP N
450 - 560 kW (600 - 750hp)
ENGINE
2 00 1
20 02 ¥ • Tier2
•|
2 00 3
2 0 04
20 0 5
6W,6S
130 - 225 kW (175 - 300hp)
6H
¥ • Tier2
NOx+HC 6.6 CO 3.5 / P M 0.2
75 - 130 kW (100 - 175hp)
4H
¥ • Tier2
NOx+HC 6.6 CO 5.0 / P M 0.3
37 - 75 kW (50 - 100hp)
4J,4LE
13 0 - 5 60 kW
6 W , 6 S,6 H
75 7 5 - 1 3 0 k W
4H
37 3 7 - 7 5 k W
4 J,4 L E
19 1 9 - 3 7 k W
L
1 3 0 - 5 60 kW
6 W ,6 S,6 H
NOx 6.0 / HC 1.0 @ •@ •@ • CO 3.5 / P M 0.2
ier-2 ¤ • T ier-2
75 7 5 - 1 3 0 k W
4H
NOx 6.0 / HC 1.0 @ •@ •@ • CO 5.0 / P M 0.3
ier-2 ¤ • T ier-2
56 5 6 - 7 5 k W
4J
37 3 7 - 5 6 k W
4 LE
19 1 9 - 3 7 k W
L
¤ • Tier2
St age2 ¥ • St
¥ • Stage2
¤ • Tier3
NOx 7.0 / HC 1.3 CO 5.0 / P M 0.4
ier-2 ¤ • T ier-2
2 01 3
2 0 14
2 01 5
Nox+NMHC 4.0 CO 3.5 PM 0.03
interim Tier4
¤ • Tier3
interim Tier4
NOx+HC 4.7 CO 5.0 / PM 0.4
NOx+HC 4.0 CO 3.5 / PM 0.2
56kw
NOx+HC 4.0 CO 5.0 / PM 0.3
¤ • Stage3-B
NOx+HC 4.7 CO 5.0 / PM 0.4
¤ • Stage3-A
NOx 3.6 CO 3.5
ier-3 ¤ • T ier-3
ier-3 ¤ • T ier-3
/ HC 0.4 / P M 0.17 NOx 3.6 / HC 0.4 CO 5.0 / P M 0.2
¤ • Tier-4 After treatment (DPF) basis
/ HC 0.7 / PM 0.25
¤ • Tier-3
NOx 4.0 CO 5.0
/ HC 0.7 / PM 0.3
LOW NOISE REQUIRME REQUIRMENT NT of EC STAGE-III STAGE-III
HC 1.0 PM 0.4
NOx+HC 4.0 CO 5.0 / PM 0.025
No pr opo sal as St St age3-B
NOx 4.0 CO 5.0
/ /
interim NOx + HC 4.7 Tier4 CO 5.0 / PM 0.03
St age3-B neary same as EPA ¤ • St
¤ • Tier-3
Nox 6.0 CO 5.0
Nox+NM HC 4.0 CO 5.0 / PM 0.03
NOx+HC 4.0 CO 3.5 / PM 0.025
¤ • Stage3-B
NOx+HC 7.5 St age3-A ¤ • St CO 5.5 / PM 0.6
¤ • Tier-3
20 12
NOx+HC 4.0 CO 5.0 / PM 0.3
St age3-A ¤ • St
NOx 8.0 / HC 1.5 CO 5.5 / P M 0.8
2 01 1
interim Tier4
¤ • Stage3-A
¤ • Stage2
NOx 8.0 / HC 1.5 •@ •@ • CO 5.5 / P M 0.8@
20 10
NOx+HC 4.0 CO 3.5 PM 0.2
¤ • Tier3
/ HC 1.0 / P M 0.3
ier-2 ¤ • T ier-2
2 00 9
¤ • Tier3
NOx 6.0 CO 5.0
NOx 7.0 / HC 1.3 CO 5.0 / P M 0.4 @ •@ •@ •
20 08
interim Tier4
NOx+HC 7.5 CO 5.0 / P M 0.4
NOx 6.0 / HC 1.0 CO 3.5 / P M 0.2
¥ • Stage2
2 00 7
¤ • Tier3
NOx+HC 6.4 CO 3.5 PM 0.2
225 - 450 kW (300 - 600hp)
¥ • Tier2
2 00 6
NOx + HC: 40% reduct reduction, ion, PM: Same Same with Tier-2 Tier-2 from Y2006 JPN Government Proposal: PM 30% lower than EPA, EC T-3
K ey Techno Technollog ie iess of Di Die es el E ng ine E G R = E xhaus x haus t G as R e-circulation E G R V alve
EEGGRR Te Techn chno oology logy Techn Te chnol ogy
Nois Te log g y Noisee Techno Technolo Technol chnolog og y I nlet Mani Manifold fold r e l o o C r e t n I
Inje Injection ction Injection Inject ion SSys ysttem em
Tota Total eeng technol og y Totalll eng Tota eng ngine ine technolog technolog technolog y -Comb -C ombus us tion cham chamber ber -Com -C ombus bus tion chamber chamber -Turbo-charging -Turbo-charging etc. etc.
BBaassee Techno Te llog oggy Technol Techno chnolo y Friction Fr iction educt uction ion Friction Fr iction RRed educt ed uction ion
E G R C o o l e r s a G R G E
Exhaust Manifold Turbo-Charging Turbo-Charging Technology Technology A i r
Tier 3 applied New Technology
Tota Total lectroni ctronic cc CControl Totalll EEle Tota lectroni le ctronic ontrol ont rol
FFuel uel Impr Improvement ovement Improvement
.
h W k / g @ • M P
Tier 2 trade-off
Tier 3 trade-off 160MPa 160MPa press pressure ure Cooled EGR Electronic control
Tier 3
70MPa pressure Inter cooler
Tier 2
JPN Tier-3 (plan) Engine Modification Limit
NOx + HC g/kW g/kWh h
4JJ1X Exhaust Emission and Fuel Consumption
Basic Information of Tier 3 Engine
•¨ Electronic Controlled Engine
1. 2. 3. 4.
Tier 2 Engine Comparison Electronic Control Common Rail System Cooled EGR
4JJ1X Engine Specifications
PPeerform rfo rma aance 44J 44B rform rfo rma nceooff 4J 4JJJJ11XX vs vs.. 4B 4BBGG11TC TC
Model Item
4HK1X
Engine model Rated output Maximum torque Cylinder arrangement and number – bore × s troke Dis plac ement Compression ratio Com pres s ion press ure Dimensions (length × width × height) W eight Fuel injection order Injection pum p type Governor type Timer type Nozzle type
(kW/min-1) (Nm/min-1)
W ater cooled, 4-cyc le, inline 4-cylinder OHC, direct injection diesel 147/2100, 12.6/2000 686/1500, 677/1500
Model Item
4HK1X
Fuel filter type Filter paper type Oil filter type Oil pump type Oil cooling type
Full flow filter Gear type
L4-ƒ L4-Ó ƒ 115×125 (mm ) (L)
5,193 17.5
MPa (psi)/rpm (mm ) (kg)
3.23 (468)/200 1043.2×829×1011.8 478 1-3-4-2 Electronic control fuel injec tion system (common (c ommon rail type) type) Electronic type Electronic type Multi-hole type
Water-cooling Am ount of engine oil Cooling s ystem m ethod Cooling water full c apac ity Water pump type
(L)
(L)
14 Centrifugal, belt type
Therm ostat type Air c leaner type Generator capacity Starter Turbocharger type Intercooler type
Oil pan•F13.0-20.5 W ater-cooled controlled circulation type
2 wax-type units Filter paper type (V-A) (V-kW )
Thermostat valve open tem perature (•Ž ) Exhaust gas recirculation device (EGR)
24-50 24-5.0 RHF-55 (IHI) Alum inium tube and end plate type 82 Installed
Model Item
6HK1X
Engine model Rated output Maximum torque Cylinder arrangement and number – bore × stroke Displacement Compression ratio Compression pressure Dimensions (length × width × height) W eight Fuel injection order Injection pump type Governor type Timer type Nozzle type
(kW/min-1) (Nm/min-1)
W ater cooled, 6-cycle, inline 4-cylinder, OHC, direct injection diesel 208/1900 1125/1500
Model Item
6HK1X
Fuel filter type Filter paper type Oil filter type Oil pump type Oil cooling c ooling type type
Full flow filter Gear type
L6-ƒ L6-Ó ƒ 115×125 (mm) (L)
7,790 17.5
MPa (psi)/rpm (mm) (kg)
304(441)/200 1356.5×995.4×1178 650 1-5-3-6-2-4 Electronic control fuel injection system (common rail type) Electronic type Electronic type Multi-hole type
Water-cooling Amount of engine oil Cooling system method Cooling water full capacity Water pump type
(L)
(L)
14.5 Centrifugal, belt type
Thermostat type Air cleaner type Generator capacity Starter Turbocharger type Intercooler type
28-38 W ater-cooled controlled circulation type
2 wax-type units Filter paper type (V-A) (V-kW )
Thermostat valve open temperature (•Ž ) Exhaust Exhaust gas recirculation device (EGR)
24-120 24-5.0 RHG6(IHI) Aluminium tube and endplate type 82 Installed
6WG1 Engine Specification Model Item Engine model Rated output Maxim um torque Cylinder arrangement and number – bore bore × stroke Dis plac ement
(kW /m in-1) (Nm /min-1)
6 WG1TQA
6WG1 XQA
TIER2 Water cooled, 4-cycle, inline 4-cylinder, OHC, direct injection diesel 235.4/1800 1275/1500
TIER2 Water cooled, 4-cycle, inline 4-cylinder, OHC, direct injection diesel 295/1800 1540/1500
(mm)
L6L6-ƒ Ó 147×154
(L)
15,681
Compression ratio
16.4
Compr Compressi ession on pressu pressure re MPa(p Pa(psi)/ si)/rp rpm m Dimensions (m m ) (length × width × height) W eight (kg) Fuel injection order Injection pump type Injection pressure press ure Governor type Timer type Nozzle type
6WG1XYSA-01 TIER3 Water cooled, 4-cycle, inline 4-cylinder, 4-cylinder, OHC, direct injection diesel 260/1800 1580/1500
16 2.75(400)/200
1462×1007×1287(with fan)
1741×1016×1340(with fan)
1462×1015×1422(with fan)
1125
1153
Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PE-P-S3S 1 7.7/ 2 2.1 RSV type Equipped
1185 1-5-3-6-2-4 Mechanical fuel injection pump (Inline fuel injection pump) BOSCH PE-P-S3S 1 7 .7/ 2 2.1 RSV type Equipped
2Stage Nozz Nozzle le Multi-hole type(8xƒ type(8xƒ 0.24mm)) Ó 0.24mm Bosch KBL2.4
2Stage Nozzle Multi-hole type(8xƒ type(8xƒ 0.24mm)) Ó 0.24mm Bosch KBL2.4
Electronic control c ontrol fuel fuel injection system (common rail type) Denso HP0 18 0MPa Elec tronic type Elec tronic type Injector Denso G2 Multi-hole type(8xƒ type(8xƒ Ó 0.19mm)ZX450 Multi- hole type(8xƒ Ó 0.21mm)ZX600/800
6WG1 Engine Specification Model Item
6WG1TQA
6WG1XQA0*
TIER2
TIER2
6WG1XYSA-0* TIER3
Fuel filter type
Cartridge(Filter paper type)
Cartridge(Filter paper type)
Filter paper type
Oil filter type Oil pump type
Full flow filter(Remote) Gear type
Full flow filter(Remote) Gear type
Full flow filter(Remote) Gear type
Oil cooling type Amou Amount nt of engi engine ne oil oil
Water-cooling (L)
Total Total 42-52 42-52 (37-47 (37-47 Oil Pan) Pan)
Cooling Cooling system syst em method m ethod Cooling water full capacity
Total Total 42-52 42-52 (37-47 (37-47 Oil Pan) Pan)
Water-coole Water-c ooled d control c ontrolled led circulatio circ ulation n type
(L) (L)
36
Water pump type
Centrifugal, belt type
Thermostat type Air Air cleane cleanerr type type
2 wax-type units @ • To be sup supp plied lied by by OEM OEM
Generator capacity
(V-A)
Starter (V-kW) Turbocharger type Intercooler type Thermostat valve open temperature(10mm)
(Ž • )
Tota Totall 42-5 42-57 7 (37 (37-52 -52 Oil Pan) Pan)
MITSUBISHI 24-50
MITSUBISHI 24-50
MITSUBISHI 24-50
MITSUBISHI 24-7.0 RHC9(IHI) Not Equipped
MITSUBISHI 24-7.0 RHC9(IHI) Equipped
MITSUBISHI 24-5.0 TD08H-31M (MHI) Equipped
83(95)
4JJ1X 4JJ1X Right Right Side Side View View Charged Air Outlet Exh Gas Outlet
(to Inter Cooler) Turbocharger
Built in Oil Cooler
SAE #3 HSG
Alternator
Oil Filter
4JJ1X 4JJ1X Left Left Side Side View View Multiple Injection Common Rail Oil Filler Cap
Confidential Aluminum Cylinder Head Charged Air Inlet (from Inter Cooler)
Water Outlet Common Rail Bell Mouth Fan Shroud (Opt.) Water Inlet Big Capacity Oil Pan
Starter Common Rail Supply Pump
TURBO CHARGER
COOLED EGR
INJECTOR (Inside of HD COV)
Common Rail Supply Pump
Remote Oil Filter
EGR Valve
Main Fuel Filter (Tandem)
EGR Cooler
Common Rail
(Tandem)
Supply Pump (G Sensor)
Turbocharger
Remote Oil Filter Port
4BG1T 4BG1T vs vs 4JJ1X 4JJ1X base base structure structure
DOHC 4 Valves Roller Follower
Multiple Injection Common Rail
(EGR Cooler) (Electronic Control EGR Valve) Built in Oil Cooler Aluminum Cylinder Head
4JJ1X SECTION VIEW
TIMING CHAIN (EGR PORT)
TIMING GEAR
4JJ1X SECTION VIEW
4JJ1X TIMING TRAIN CAM SHAFT ; EXHAUST
CAM SHAFT ; INLET
TIMING CHAIN
Oil Drain speed improved
FUEL SUPPLY PUMP
VACUUM PUMP (For Vehicle Use Only) CRANK
P/S PUMP (For Vehicle Use Only)
OIL PUMP
Crank Crank case case remo removal val needs needs to remov removee Cyl Head Head Cyl Cyl Head ead
Cyl Cyl Body ody
Gear Case Assy
Crank Case Oil Pan
(Lubrication for improv ed abrasion resistance) (High rigidity of cylinder head) (Improved com co mbus usti tion on,, High power, High rigidity)
Ê Roughness 5ƒ
Roughness 3ƒÊ (Reduced oil consumption)
/ /
80/64
6BG1TC
(High rigidity, y, High power)
4/6HK1TC
82/73
(Hig (H igh h pow er er))
6WG1X
Nois No isiseecom co m Nois No com co mppaaris risoonn 44JJJJ11XX vs vs.. 44BBGG11TC TC
9 5
dB 3 Reduct
4JJ1X
9 0
•œ\•
\• •œ
ion
8 5
4BG1TC
8 0
7 5 J un.17.' un.17.'0 5
7 0 6 0
8 0
10
12 0
14 0
1 60
18 0 0
2 0 0
20 0
24 00
26 0
LLubri ub rica cat ttion con um ppttion oof ooil 44B B 11TC ubri ub rica cat ion cons conssump cons ump um ion of off oil oilil 44JJJJ11XX vs vs.. 4B TC
4BG1TC 4JJ1X
4JJ1X oil consumption
30% reduction in ISUZU test
-
4JJ1X Sensor/Actuator layout
4HK1X Sensor Locations Boost pressure sensor G (cam) sensor Crank sensor Coolant temperatur e sensor Common rail pressure sensor Boost temperature sensor Oil pressure sensor
Fuel temperature sensor •kVehicle equipment•l kVehicle E Am •@ Ambi bient ent te temp mper erat atur ure e sen senso sor r E At •@ Atmo mosp spher heric ic pre press ssur ure e sens sensor or
Ambient Temperature Sensor
Vehicle Front Side Atmospheric Pressure Sensor Air Cleaner
Coolant Temperature
Engine LH
Engine Rear
6H
Common Rail Pressure
Boost Temperature
Fuel Temperature
Boost Pressure
Oil Pressure
4H
Crank Position
Cam Position
6WG1X Sensor Layout
Name 1.Pressure Control Valve 2. Fuel Temperature Sensor 3. G Sensor (Cam speed) 4. Boost Temperature Sensor 5. Common Rail Pressure Sensor 6. Engine Coolant Temp. Sensor
7. EGR Valve 8. Boost Pressure Sensor 9. CKP Sensor (Crank speed) 10. Engine Oil Pressure sensor 11. Overheating Switch
Engine Control •@
Basic In Injection Co Control i• Injection Quantity• AInjection Pressure• AInjection Timing• AInjection Rate• j
•@ Fuel Injection Compensation AAltitude Compensation• AOver Heat• j i• Starting Fuel Compensation•
@ • EGR •@Anot Anothe herr Engi Engine ne Con Contr trol ol •@
Idling control
•@
QOS
•@
Selfelf-d diag iagnostic stic fun functi ction
@
CAN communication
mm3/st• mm3/st j•
ECM adjust Starting Fuel Quantity by Coolant Temperature Sensor signal
Gƒ G ƒ “ƒ Wƒ W ƒ “ƒ N ƒ [• ‰ ƒ “ƒ g‰ gƒ‰ · “x
(deg C)
ECM adjust maximum Fuel Quantity by Atmospheric Pressure Sensor signal
In addition Alarm raise abov Fuel Quantity decrease abov 100
6H/4HK1/4JJ1
Q Trim
Torque 1000RPM
1500RPM
RPM
2000RPM
Satellite Communicatio n
ICF CAN Bus
MC
CAN Bus ECM
Dr.ZX
Common Rail
Supply Pump
Injector
ECM
Common Rail
Injector
Supply Pump ECM )
Exploded View
SCV
IN
Filter Fuel temperature sensor Feed pump Regulating valve
Pump body Ring cam Camshaft
OUT
Injector
Common Rail
Injector Hole Diameter ZX 450-3: 450-3: 8-ƒ³0.1@ •9 ZX 650/800-3: 650/800-3: 8-ƒ³0.21
Supply Pump ECM
Can Lift Open Valve PCV Operation Close Valve Close Valve
To Common Rail
Delivery Valve Plunger
Flow damper
Common rail pressure sensor
Pressure limiter
Pressure Limiter opens to release the pressure if abnormally high pressure is generated. It resumes operation (closes) after the pressure falls a certain level.
Pressure limiter
Sample of Rail Pressure
j •i Rail Pressure Sensor•
) t s / 3 m m (
160MPa
y t i t n a u Q l e u F
100 – 150MPa
70 – 90MPa
30 – 60MPa
Rail Pressure Sensor Engine Speed (rpm)
6HK1
Approx. 160MPa
Q
Approx. 30MPa 2000RPM
900RPM
RPM
Flow damper
Reduce the pressure pulsations in the pressurized line and also prevent abnormal discharge of fuel
CMP sensor detects the camshaft rotation and identifies the cylinder.
CKP sensor detects the engine speed.
d‚ ‚df‚ f‚ ‚q
Layout
4.
Negative Positive High Press. Over Flow
Engine
Fuel Cooler
Fuel Tank
Common Rail
Pre. Filter
Main Filter
Feed Pump
Fuel Pumo
Plunger Regulator Supply Pump
Fuel Pump Pre. Filter
Filter Wrench (Pre, Main common
Main Filter Priming Pump
OIL PAN• j
Drain Cock
Drainer i
hicl hicl j
Change sealing line Not Reuse
World Fuel Map for Off-road Machine
2005.4.14
Level of Co n s id e rati atio n
• E S u lfurc ont ontent ents • G @• @• @1000• ` 3 00 0p 0p m / EWate E •Wate r conte n ts • E Du s t co n t ents • E F u e l visco visco s ity ; • @ HFRR 460• 60• ` 560 / • E A d i tive• @• @
Dang re abo v e3 0 00 00p m
Ne d
Care
Good
Unkown
above above 6 00 N . Europe S u lfu r W a ter D u st iV scos scosit it Ad i tive
A C NAD NADA S u lfu r W a ter D u st iV scosit scosit Ad i tive
EU S u lfu r W a ter D u st iV scos scosit it Ad i tive
N . America S u l fu r W a ter D u st iV scosit scosit d A ditive ditive
N . Afri Afric ca
.A S .A e m rica u S l fu r a W er u D st V is cosit A d id t ive
S u l fu r W a ter D u st iV scos scosit it d A ditive ditive
u lS fur W a ter D u st iV scos scosit it d A ditive ditive
.ERussia
W.Rus s i a
u lS fu r a W er u D st iV c so is t
S u l fu r W a ter D u st iV scos scosit it d A ditive ditive
.E .M E ast S fu l u r W a ter D u st iV scosit scosit Ad i tive
d A ditiv e
Chi Chn i C • a E.Asia
S u lfu r W a ter
u lS fu r a W ter ter D st V c s i osit d A ditive ditive
.E .SE .Asia S u lfu r
a W ter ter D st V c s i o s it Ad i tive
.S Africa
JA PAN
S u lf u r W a ter D u st iV scos scosit it Ad i tive
O s ean i a S lu fu r a W ter ter u D st V s i cosi cosit d A ditive ditive
Tier-3 Engine major specification and Maintenance point 1.High pressure fuel injection control by common rail system. Prohibit teardown and re-adjustment of injector. Prohibit re-use of injector pipe and high pressure fuel pipe. Must be keep ISUZU fuel requirement. Keep observe strictly the maintenance schedule.
AGAIN
2.Electronic control module. notice : A battery cable must be disconnect at the time of welding work for ECM protection. 3.Cooled EGR Must be keep ISUZU fuel requirement. Must be keep ISUZU Engine oil requirement and maintenance. Observe engine strictly of Maintenance.
SCAN Tool
Monitor
Dr.ZX
ZX ZX-3 Dr.ZX
@Tech2 •@Tech2
As ZX-3 type machine scan tool, Dr.ZX add the new function of engine failure detection •Ë Main Scan Tool
Monitor also able to scan the failure of vehicle and engine and to monitor
operating condition.
Isuzu prepare Tech2 for Isuzu service network•@
(Special Tool) Breaker Box Harness Checker
(Special Tool) Injector Checker ’
A. Diagnostic process with an interview 1) Confirm user complain. 2) Carry out preparative inspection. 3) Confirm service information. 4) Confirm DTC code. 5) Confirm phenomenon by visual observation. B. Repair C. Check
“Trouble Shooting Manual ” – • Confirmation process from DTC code. •@ ‡ Confirm DTC code by c‚ c‚ ’‚•D‚y‚w or Monitor. A ‡ To translate Hitachi DTC code to Isuzu DTC code •@ B• B ‡@ • To read/confirm the pages which described Table of DTC code on trouble shooting manual. •@ C• C ‡@ • To read detail description of each DTC code.@ • – • Confirmation process from phenomenon. @ •‡ Confirm failure phenomenon. A• ‡ @To @To read/confirm the pages which described Table of phenomenon. @ •B ‡ •@ To re read de detail description of of ea each fa failure.•@
About Tech2
S Tool)
Performs Reading, confirma tion and clearing of DTC Displays the current data recognized andcontrolled by ECM Records and plots data when trouble occurs Enables to confirm the history of data when ECM is replaced Checks operation and function at each test and confirms abnormality
Tech2 Diagnostic test was completed at previous ignition cycle. Diagnostic test was accepted at current ignition cycle. Faults found by the diagnostic test do not currently exist.
Diagnostic test was completed at previous ignition cycle. The faults detected by the diagnostic test currently exist. The faults exist at the current engine cycle.
‚c‚’• c‚ ’D‚ D • ‚y‚ yw ‚
’
Injector QR Code
Engine Label
ISUZU Industrial Engine Diagnostic Tool
-•@2007 2007.. Jan Jan 17. 17. –• –@ •
Off-highway Powertrain Operation Dept. Planning & Service Group
EMPS-III Position
Major or O EM sama
Minor OEM Sama ( no own scan tool)
Own Sca Sca n Tool
EMPS-III
Diagnostic Scan Tool
DTC CAN CA N/ KW Comm Co mmu unicatio ni cation n Engine control module -- ECM
Data parameter EMPS-III
Snapshot
Actuator Actuator test Software to reflash
EEPROM Diag Lamp
Tech2 KWP2000
Unique Data
Trouble Shooting Manuals
CAN
Monitor tor on the machine Controller onthe machine
Data parameter
--ECU
OEM scan tool CAN Comm Co mmu unicatio ni cation n
Engine control module -- ECM
DTC
Injector Injecto r checker checker
Tool to rewrite EMPS‡U
Snapshot
Actuator Actuator test Software to rewrite
EEPROM Tech2
EMPS‡V
KWP2000
Unique Data
Trouble Diagnostic Procedure
When Parts is replaced
Injector QR code ECM S of of t r ep e plac e No n e ed e d* 1 ECM h ard re pl plac e Write In je c t or r e plac e Writ e EGR r e plac e No n e e d S u pply P u mp re plac e No n e ed
EGR EGR Supplu Supplu P ump initialization Initialization No n e e d* d* 1 Lat es e s t P ar art s No adju s t t o z e ro ro p No n e e d Writ e * 2 Lat e s t Pa rt r ts No No adju s t to z er e ro p No n e ed ed f o r 2 4 V No n e e d No n e e d No n e e d No n e e d No n e ed ed Ch e c k in t 'bilit y adju s t t o z e ro p No n e ed ed No n e e d No n e e d No n e e d No ne ed f or 2 4 V Q T rim
S o ft ,Calib
*1 means , not n ec es sary at at t his mom moment ent , if n ee d, bulle bulletin tin is iss ued. * 2 means me ans Engi Engine S e rial rial Number Number s hould be import imported ed from f rom EMPS• PS •A ch ange Q Trim Trim @ •@ •@ •@ •@ •@ • is c onduc te d by pers ons in ISZ ISZ o rganizat rganizatiion u nder re gulation. gulation.
EMPS EMPS III III vs vs TE TECH CH II EMPS - I II TECH- I I Fun ct io n Diag DTC KW KW20 00 Dat a P arame t e r Snap S hoo t Ac t uat or Te s t Rail P re s s u re Te st st Inject or Bala alance T est Engine RP M a dju s t P re - In Inje c t io n T e st Injecti njection on Tim Timing Test Test Inje c to to r Forc e Drive Glow Re lay Te s t EGR T e st Graph Dis play QR Co de Q Trim Engine Seri Serial Number ECM S wap Re flas h Re flash QR ECM S wap Factory actory QR,Q QR,Q Tri Trim Data Data
Remark TIS20 00
•@ › •@ › •@ › •@ › •@ › •@ ›
•@ › •@ › •@ › •@ › •@ › •@ › N/ A
•@ › •@ › •@ › •@ › •@ › @ •› •@ ›
by Mac h ine s ide
•@ › @ •› •@ › •@ › •@ › N/ A N/ A N/ A N/ A
@ •› •@ › •@ › •@ ›
N/ A
@ •› •@•@(•› ) •@•@ •› •@•@ •› N/ A N/ A N/ A N/ A
•@ › P as s word
Languages Diagnosis Reflash
8 Lang Lang uages uages Japane Japaness e, Engli English, sh, Spanis Spanish, h, French French,, @ P • ortugues e•AChinese• AChinese•AGermany• AGermany•AItalian AItalian
Trouble Sh Shooting Man Manuual Japanese, English
@ •
Serial/U Serial/U SB adaptoradaptor-
Many countries have different type of plugs. Repl Replace thi s part .
189
SST. EMPS-III EMPS (Engine Module Programming System ) POWER SUPPLY
(Plug may be locally supplied)
AC100-AC240V BATTERY DC12V or DC24V DC out put is based on ECM power voltage DC current more than 2.5A CONNECTER : SIZE (cm) W
Description (Part No.) EMPS (N/A)
WEIGHT
D
RS-232C H
Max. 180
110
40
Min. 180
105
30
350g
EMPS-III Lap Top requirement
CPU •@Pent Pentiu ium m 1.6G 1.6GHz Hz or or bett better er Memo emory Min 256 M byte or more C drive available 20G or more •@ XP reco recomm mmen ende ded, d, not not app appli lica cabl blee to to 98 98
Reflas lash procedure CDROM•quarterly @ quarterly Can confirm parts number before and after
ECM Enginee ring Version
compresed•@ S19 File by email
certified CD
Can conf conf irm parts parts number before and after
06/4 - sta started b y OEM OEM in Canada